Ultrasonic Additive Manufacturing of Multi-Material Structures

多材料结构的超声波增材制造

• 批准号: 1538275
• 负责人: Marcelo Dapino
• 金额: $ 30.04万
• 依托单位: Ohio State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2015
• 资助国家: 美国
• 起止时间: 2015-09-01 至 2018-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1538275&HistoricalAwards=false
• 关键词: Ultrasonic; Additive; Manufacturing; Multi; Material

Ultrasonic additive manufacturing is a solid-state additive process for fabrication of fully-dense metal structures from foil stock. When combined with subtractive processes, it can be used to fabricate 3D structures that incorporate dissimilar metals (e.g., aluminum, copper, and titanium), internal conformal channels for cooling and other transport purposes, and temperature-sensitive components such as sensors, reinforcement fibers, electronic circuits, fiber optics, and smart materials. A lack of scientific understanding of the process and how it affects build properties currently limits the quality and size of builds and the range of dissimilar material combinations that can be additively welded. This award supports fundamental research in order to understand its complex process-property relationships and enable in-situ process quality monitoring using hardware that already exists in commercial equipment. Results from this research will lead to increased use of this US-based manufacturing technology in the automotive, aerospace, biomedical, and electronics industries. The research objective is to correlate macroscopic energy transfer effects (i.e., electromechanical transduction in the welder, vibrational energy imparted by sonotrode on foil, and effects of mechanical compliance on the energy available to dynamically recrystallize the microstructure) with details of the microstructure at the weld interface and mechanical properties of ultrasonic additive manufacturing builds. First-principles thermodynamic models will be formulated to describe the complete flow of energy in the ultrasonic additive manufacturing process, including system level electromechanical relationships in the welder (using classical electroacoustics theory) and quantification of the energy available to recrystallize the microstructure (from thermodynamic balances between input weld energy, surface and bulk energies, and losses). In-situ experimental techniques for measuring shear force at the sonotrode will be integrated with measurements of weld vibration amplitude, voltage, and current to validate the energy models. These validated models will be used to predict process-property relationships in new material combinations (e.g., ultra high strength steels and titanium), enable new 3D weld configurations, optimize process parameters without massive experimental trials, and provide the basis for a new power-based process control framework that overcomes current quality, size, and real-time process monitoring limitations. A key aspect of intellectual merit is that this will be the first comprehensive energy mapping of the ultrasonic additive manufacturing process and also the first to be experimentally verified by both in-situ weld power measurements and microstructural analyses.

超声增材制造是一种固态增材工艺，用于从箔材制造全致密金属结构。当与减成法相结合时，它可以用于制造包含不同金属的3D结构（例如，铝、铜和钛）、用于冷却和其他运输目的的内部共形通道以及温度敏感部件，例如传感器、增强纤维、电子电路、光纤和智能材料。目前，对该工艺及其如何影响构建特性缺乏科学的理解，限制了构建的质量和尺寸以及可以添加焊接的不同材料组合的范围。该奖项支持基础研究，以了解其复杂的工艺-性能关系，并使用商业设备中已有的硬件实现现场工艺质量监控。这项研究的结果将导致这种美国制造技术在汽车、航空航天、生物医学和电子行业的使用增加。研究目标是将宏观能量传递效应（即，图1示出了在焊接界面处的微观结构的细节和超声增材制造构建的机械性能的示例性分析（例如，焊接机中的机电转换、由超声波焊极在箔上赋予的振动能量、以及机械顺应性对可用于动态再结晶微观结构的能量的影响）。将制定第一原理热力学模型来描述超声增材制造过程中的完整能量流，包括焊机中的系统级机电关系（使用经典电声理论）和可用于再结晶微观结构的能量的量化（来自输入焊接能量、表面和体积能量以及损耗之间的热力学平衡）。 在超声焊极测量剪切力的现场实验技术将与焊接振动振幅，电压和电流的测量，以验证能量模型。这些经过验证的模型将用于预测新材料组合中的工艺-性能关系（例如，超高强度钢和钛），实现新的3D焊接配置，优化工艺参数而无需大量的实验试验，并为新的基于功率的过程控制框架提供基础，克服当前的质量，尺寸和实时过程监控限制。知识价值的一个关键方面是，这将是超声增材制造过程的第一个全面的能量映射，也是第一个通过原位焊接功率测量和微观结构分析进行实验验证的。