A Method for Bond Strength Evaluation for Laminated Structures with Application to Ultrasonic Consolidation

Zhang, Chunbo; Deceuster, Andrew; Li, Leijun

doi:10.1007/s11665-008-9342-1

Cited by 34 publications

(20 citation statements)

References 18 publications

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“…Interlaminar shear stress was tested with a custom designed shear sample inspired from ASTM International standards specification D3165-07 while out-of-plane delamination was evaluated with a pushpin sample design. The push-pin sample design was based on tests by Zhang et al 10 and other UAM bond assessments. 11 Schematics of these sample designs can be seen in Fig.…”

Section: B Mechanical Characterizationmentioning

confidence: 99%

Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

2014

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Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process that combines additive joining of thin metal tapes and subtractive computer numerical control milling operations to generate near-net shape metallic parts. We conducted a design of experiments study with the goal to optimize UAM process parameters for aluminum 6061. Weld force, weld speed, amplitude, and temperature were varied based on a Taguchi L18 experimental design matrix and tested for mechanical strength using a shear test and a comparative push-pin test. Statistical methods including analysis of variance (ANOVA), mean effects plots, and interaction effects plots were conducted to determine optimal process parameters. Results indicate that weld amplitudes of 32.76 lm and weld speeds of 84.6 mm/s yield maximum mechanical strength while temperature and force are statistically insignificant for the parameter levels tested. Annealing of cold-worked foil stock produces a 13% strength increase for UAM samples over homogeneous annealed material.

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Section: B Mechanical Characterizationmentioning

confidence: 99%

Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

2014

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“…on the mechanical properties of the UAM builds [4][5][6]. A wide range of testing methodologies including peel tests [4,5], tensile and shear tests [6] have been used to evaluate the mechanical strength [7]. Often, 85% reduction in strength along the Zdirection has been observed in comparison to that of bulk monolithic material [2].…”

Section: Introductionmentioning

confidence: 99%

Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

et al. 2016

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“…Offline ultrasonic NDE can also be used to calculate the elastic constants of UAM components and image internal features such as Type-1a defects [26]. NDE studies need to be backed up with destructive correlation which can be achieved through the means of a push-pin test proposed by Zhang et al [20]. Other mechanical tests such as lap-shear and tensile have been shown to be correlated to area under push-pin loaddisplacement curves which represents the work done in extruding 10-15 UAM layers in a 3-point bend configuration.…”

Section: Sensitivity Analysis On the Inversion Scheme Indicates That mentioning

confidence: 99%

“…The oil provides coupling between the transducer and the base plate so that the quality of the UAM stack can be measured from the bottom of the base plate. Previously[96], contact transducers were experimented with but due to the vibration during UAM, coupling was lost with the base plate during manufacturing.Evaluating the mechanical strength of the UAM components is often performed by pushpin testing[20,98]. It involves pushing out a set of UAM layers in a three-point bend configuration.…”

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Ultrasonic nondestructive evaluation of metal additive manufacturing.

Nadimpalli¹

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Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of processstructure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the UAM process, an in-situ quality evaluation technique was desired. Several NDE techniques were tested in a lab environment before ultrasonic NDE was chosen as a practical, robust, and cost-effective NDE tool. An in-situ monitoring setup was designed and built on an UAM system. NDE results showed interesting features that were simulated through analytic and finite element wave-propagation models. AM layers with defects were characterized as an intact layer and a finite interfacial stiffness spring. The spring stiffness vi coefficient is a quality parameter that was used to characterize AM layers through a modelbased inversion method. In-situ and post-process NDE provided an understanding of defect generation and propagation in UAM. A novel solid-state repair mechanism based on Friction Stir Processing (FSP) was proposed and demonstrated. The quality of L-PBF components depends on several factors including laser power, scan speed, hatch spacing, layer thickness, particle shape/size distribution and other build conditions. Developing process parameters for a new material is an expensive and complex optimization problem. Post-process ultrasonic NDE tests revealed that the model-based insitu quality monitoring developed for UAM is also applicable to L-PBF Additive Manufacturing. A similar NDE setup was designed and installed on an open-architecture L-PBF system. A layer-by-layer bond quality evaluation demonstrates the ability to detect good-quality bonds hidden behind poor-quality regions for Inconel 625 alloy. A costeffective, process parameter development methodology has been proposed and demonstrated. vii TABLE OF CONTENTS

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A Method for Bond Strength Evaluation for Laminated Structures with Application to Ultrasonic Consolidation

Cited by 34 publications

References 18 publications

Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

Ultrasonic nondestructive evaluation of metal additive manufacturing.

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