Ultrasonic Rapid Manufacturing of Meso/Microscale Functional and Active Structures

超声快速制造介观/微米级功能和活性结构

• 批准号: 0114309
• 负责人: Peter Wong
• 金额: --
• 依托单位: Tufts University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2001
• 资助国家: 美国
• 起止时间: 2001-09-01 至 2006-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0114309&HistoricalAwards=false
• 关键词: Ultrasonic; Rapid; Manufacturing; Meso; Microscale

This program will introduce and analyze a new rapid manufacturing technology for fabrication of functional miniature devices with integrated intelligent structures and encapsulated components. This will be based on the ultrasonic welding (USW) process, a solid-state, cold joining technique, yielding strong bonding between dissimilar metals and other materials. Ultrasonic rapid manufacturing (URM) will utilize multiple material foils and fibers, that will be bonded in subsequent layers, followed by ultrasonically assisted diamond scribing to the proper contours. Fundamental understanding and comprehensive modeling of microscale USW, will be addressed by a hybrid experimental and computational process analysis. Extensive characterization of the joint structure and properties of aluminum bonds to other selected metal alloys will be performed in the laboratory. Knowledge gained from this research will define optimal process conditions, allow intensive study of microscale material effects, making it accessible through incorporation in a continuous ultrasonic transformation database. Numerical simulation of the interdependent mechanical, thermal and diffusion distributions during the USW process will be conducted in concert with the experimental work. Researchers at Tufts University and Northeastern University will collaborate on this project.This URM research will be connected with the engineering curriculum to leverage rapid manufacturing education. This will be promoted by a new undergraduate/graduate course on Rapid Prototyping, Tooling and Manufacturing, as a basis for a future Rapid Manufacturing minor; a new SFF and Microfabrication Seminar series with invited industry experts; and an annual Rapid Manufacturing Contest for undergraduate student groups nationwide. The program will involve close collaboration of the partnering institutions. Industrial sponsorship through in-kind equipment and technical support will also be provided by Axcelis Technologies, Honda R&D Americas and Stapla Ultrasonics. The benefits of the new technology will be harnessed in the design and fabrication of miniature multi-material internal structures, with embedded prefabricated elements (sensors, actuators, processors, MEMS etc), providing multi-domain functionality in mechatronic, optoelectronic, microfluidic, biomedical microdevices etc.

本节目将介绍和分析一种新的快速制造技术，用于制造集成智能结构和封装元件的功能微型器件。这将基于超声波焊接(USW)工艺，这是一种固态冷连接技术，可在不同金属和其他材料之间产生牢固的结合。超声波快速制造(URM)将利用多种材料的箔和纤维，这些材料将在后续的层中粘合，然后在超声辅助下将钻石划线到适当的轮廓。对微尺度超短波的基本理解和全面建模，将通过混合的实验和计算过程分析来解决。实验室将对铝键与其他选定金属合金的连接结构和性能进行广泛的表征。从这项研究中获得的知识将确定最佳工艺条件，允许深入研究微尺度材料效应，使其能够通过纳入连续的超声波变换数据库来获取。我们将结合实验工作，对超短波过程中相互依赖的力学、热和扩散分布进行数值模拟。塔夫茨大学和东北大学的研究人员将在这个项目上合作。这项URM研究将与工程课程相联系，以利用快速制造教育。这将通过新的本科/研究生课程快速成型、模具和制造，作为未来快速制造辅修的基础；与受邀的行业专家举行的新的SFF和微制造系列研讨会；以及面向全国本科生团体的年度快速制造竞赛来促进这一点。该计划将涉及合作机构的密切合作。Axcelis Technologies、本田研发美洲公司和Stapla超声波公司也将通过实物设备和技术支持提供行业赞助。新技术的优点将被用于设计和制造微型多材料内部结构，并嵌入预制元件(传感器、执行器、处理器、MEMS等)，在机电、光电、微流体、生物医学微设备等领域提供多领域功能。