A comprehensive review of ultrasonic additive manufacturing

Hehr, Adam; Norfolk, Mark

doi:10.1108/rpj-03-2019-0056

Cited by 76 publications

(31 citation statements)

References 81 publications

(90 reference statements)

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For example, the resulting components nominally have anisotropic properties (due to the solidified, columnar microstructure), alloys can undergo constitutional undercooling, and the processing must be carefully controlled and monitored to prevent casting-type defects from occurring [1]. In contrast, solid-state technologies, such as binder-jetting and ultrasonic methods, overcome these fusion limitations but have their own drawbacks [2,3]. These limitations include difficulties reaching full density (for binder-jet) and, for ultrasonic technologies, difficulty with residual stresses/strains in the build as well as limited ability to resolve fine component features.…”

Section: Introductionmentioning

confidence: 99%

Microstructure Development in Additive Friction Stir-Deposited Cu

Priedeman

Phillips

Lopez

et al. 2020

Metals

View full text Add to dashboard Cite

This work details the additive friction stir-deposition (AFS-D) of copper and evaluation of its microstructure evolution and hardness. During deposition, a surface oxide is formed on the deposit exterior. A very fine porosity is formed at the substrate–deposit interface. The deposit (four layers of 1 mm nominal height) is otherwise fully dense. The grains appear to have recrystallized throughout the deposit with varying levels of refinement. The prevalence of twinning was found to be dependent upon the grain size, with larger local grain sizes having a higher number of twins. Vickers hardness measurements reveal that the deposit is softer than the starting feedstock. This result indicates that grain refinement and/or higher twin densities do not replace work hardening contributions to strengthen Cu processed by additive friction stir-deposition.

show abstract

Section: Introductionmentioning

confidence: 99%

Microstructure Development in Additive Friction Stir-Deposited Cu

Priedeman

Phillips

Lopez

et al. 2020

Metals

View full text Add to dashboard Cite

show abstract

“…These are followed by binder jetting and material extrusion (ME) [ 142 , 143 ]. The less industrially known AM technologies, which use ultrasonic, friction, and friction stir welding, together with thermal spraying (e.g., cold spraying), also present high potential [ 144 , 145 , 146 ]. Their main advantages compared to PBF and DED are in the possibilities to join dissimilar materials, better energy efficiency, smaller heat input, a protective chamber or atmosphere generally not being needed, and a promising buy-to-fly ratio.…”

Section: Additive Manufacturing Processesmentioning

confidence: 99%

“…Further progress in solving CRM-related challenges belongs to the developing trends in AM and its deep integration with other processing modalities. Several AM-related possibilities to reduce and optimize the use of CRMs and CRM-based materials are discussed in this review: Use of hybrid manufacturing [ 138 , 146 , 174 ]; Production of multimaterial components [ 175 , 176 ]; Production of functionally graded materials (FGMs) [ 153 , 165 , 177 , 178 ]; Repairing and remanufacturing using additive manufacturing [ 143 , 178 , 179 , 180 , 181 , 182 ]. …”

Section: Modern and Future Trends In Additive Manufacturing Of Crmmentioning

confidence: 99%

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

et al. 2021

View full text Add to dashboard Cite

The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

show abstract

“…The microstructure of the UAM parts has been studied by many researchers for different substrate materials and combinations, but has not been systematically reviewed. There has been several review papers on UAM [37,38], but they did not cover the microstructure evolution in detail. It is believed that a review on the microstructure evolution will help to understand the bonding mechanisms, the good practice, the capability and the influence of different process parameters on build quality of UAM.…”

Section: Introductionmentioning

confidence: 99%

A review of microstructure evolution during ultrasonic additive manufacturing

2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Ultrasonic additive manufacturing (UAM) is a solid-state metal additive manufacturing process, with the combination of layer by layer ultrasonic seam welding and CNC machining. Due to the friction and deformation at the bonding interface, the ultrasonic softening effect and temperature generated, the microstructure of the substrate materials is evolving constantly. In this paper, in order to better understand the bonding mechanisms, the good practice and the capability of UAM, and the influence of different key process parameters on bonding quality, the microstructure evolution during UAM is reviewed in detail. Defects can be generated at the UAM bonding interface, but by choosing the right material combination and the right process parameters, defects can be reduced to minimum. Plastic deformation is very important for the bonding between layers during UAM, and plastic flow is important for redistribution of oxide layer, forming of mechanical interlocks, filling micro-valleys on the mating surface, and filling the gaps when embedding elements. UAM process can cause recrystallization and grain refinement at the welding interface and the intimate bulk materials around, and it will also gradually change the texture from rolling texture to shear texture. In the meantime, when further layers of materials are deposited on the top of the existing part, the microstructure will have some accumulative change. In order to reduce the defects number and increase the strength, sometimes, heat treatment needs to be carried out to the as-deposited parts, which will change the microstructure as well. Finally, the relevant research is summarised and the perspectives of further research are recommended.

show abstract

A comprehensive review of ultrasonic additive manufacturing

Cited by 76 publications

References 81 publications

Microstructure Development in Additive Friction Stir-Deposited Cu

Microstructure Development in Additive Friction Stir-Deposited Cu

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

A review of microstructure evolution during ultrasonic additive manufacturing

Contact Info

Product

Resources

About