Abstract:Ultrasonic additive manufacturing (UAM) is a novel solid-state freeform fabrication process that utilizes ultrasonic energy to merge similar/dissimilar metal tapes. Metallurgical bonding between the metal tapes can be achieved instantaneously once the sonotrode rotates through. Herein, five-layered Al-1100 ultrasonically consolidated samples are fabricated under various parameter combinations of ultrasonic amplitude and normal force settings. The microstructure and texture evolution of the built component amon… Show more
“…Similarly, Li et al [396] observed formation of fine sub-grains by progressive lattice rotation locally at the interfaces in Al-1100 during USAM while bulk of the layers retained the starting microstructure (Figure 40). Figure 40. EBSD-based IPF map showing the recrystallised microstructure at the interface of Al-1100 similar joint [396]. …”
Section: Computational Modelling Of Microstructural Evolutionmentioning
confidence: 53%
“…Babu and co-workers [391][392][393][394][395] have reported extensively on the evolution of microstructure during USAM in material systems such as Al/Ti and Cu/Cu in which they suggested that the metallurgical bonding between plates is enhanced by the occurrence of DRX and subsequent grain boundary migration across the interface. Similarly, Li et al [396] observed formation of fine sub-grains by progressive lattice rotation locally at the interfaces in Al-1100 during USAM while bulk of the layers retained the starting microstructure (Figure 40).…”
This review article provides a critical assessment of the progress made in computational modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict physical phenomena, concepts of microstructural evolution, residual stresses, role of multiple thermal cycles, and formation of multi-dimensional defects along with the achieved degree of experimental validation. The uniqueness of this article stems from the inclusion of comprehensive information on computational progress in the field of fusion-based, sintering-based, and mechanical deformation-based AM. A computational model's role in determining the process framework for the desired outcome of the set properties of the AM components is recognised while presenting the process-microstructure maps, thereby appraising computational ability towards the qualification of products. The inclusion of a detailed discussion on the bi-directional coupling of machine learning and physics-based computational models provides a futuristic roadmap for the digital twin of metal-based AM.
“…Similarly, Li et al [396] observed formation of fine sub-grains by progressive lattice rotation locally at the interfaces in Al-1100 during USAM while bulk of the layers retained the starting microstructure (Figure 40). Figure 40. EBSD-based IPF map showing the recrystallised microstructure at the interface of Al-1100 similar joint [396]. …”
Section: Computational Modelling Of Microstructural Evolutionmentioning
confidence: 53%
“…Babu and co-workers [391][392][393][394][395] have reported extensively on the evolution of microstructure during USAM in material systems such as Al/Ti and Cu/Cu in which they suggested that the metallurgical bonding between plates is enhanced by the occurrence of DRX and subsequent grain boundary migration across the interface. Similarly, Li et al [396] observed formation of fine sub-grains by progressive lattice rotation locally at the interfaces in Al-1100 during USAM while bulk of the layers retained the starting microstructure (Figure 40).…”
This review article provides a critical assessment of the progress made in computational modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict physical phenomena, concepts of microstructural evolution, residual stresses, role of multiple thermal cycles, and formation of multi-dimensional defects along with the achieved degree of experimental validation. The uniqueness of this article stems from the inclusion of comprehensive information on computational progress in the field of fusion-based, sintering-based, and mechanical deformation-based AM. A computational model's role in determining the process framework for the desired outcome of the set properties of the AM components is recognised while presenting the process-microstructure maps, thereby appraising computational ability towards the qualification of products. The inclusion of a detailed discussion on the bi-directional coupling of machine learning and physics-based computational models provides a futuristic roadmap for the digital twin of metal-based AM.
“…The texture of the bottom layer and the evolution of microstructures is a function of input energy. The effect of ultrasonic energy on the microstructure evolution at the bonding regions was further discussed (Li et al , 2021).…”
Section: Process Improvements In Ultrasonic Additive Manufacturingmentioning
Purpose
This study aims to outline the current challenges in ultrasonic additive manufacturing (AM). AM has revolutionized manufacturing and offers possible solutions when conventional techniques reach technological boundaries. Ultrasonic additive manufacturing (UAM) uses mechanical vibrations to join similar or dissimilar metals in three-dimensional assemblies. This hybrid fabrication method got attention due to minimum scrap and near-net-shape products.
Design/methodology/approach
This paper reviews significant UAM areas in process parameters such as pressure force, amplitude, weld speed and temperature. These process parameters used in different studies by researchers are compared and presented in tabular form. UAM process improvements and understanding of microstructures have been reported. This review paper also enlightens current challenges in the UAM process, process improvement methods such as heat treatment methods, foil-to-foil overlap and sonotrode surface roughness to increase the bond quality of welded parts.
Findings
Results showed that UAM could solve various problems and produce net shape products. It is concluded that process parameters such as pressure, weld speed, amplitude and temperature greatly influence weld quality by UAM. Post-weld heat treatment methods have been recommended to optimize the mechanical strength of ultrasonically welded joints process parameters. It has been found that the tension force is vital for the deformation of the pre-machined structures and for the elongation of the foil during UAM bonding. It is recommended to critically investigate the mechanical properties of welded parts with standard test procedures.
Originality/value
This study compiles relevant research and findings in UAM. The recent progress in UAM is presented in terms of material type, process parameters and process improvement, along with key findings of the particular investigation. The original contribution of this paper is to identify the research gaps in the process parameters of ultrasonic consolidation.
“…Texture analysis using electron backscattered diffraction (EBSD) or neutron diffraction has been confirmed as a useful method to study the forming process of metal during UAM [3, 4, 10, 11, 13, 19, 20-28]. It was found that the recrystallised microstructure with 111 shear texture mainly formed in the vicinity of the consolidated interface which experienced great plastic deformation [19, 21, 23, 27], while the rolling texture such as are usually attributed to compressive deformation resulting from the normal load applied by the ultrasonic sonotrode [4, 13, 19].…”
Interfacial texture and bonding strength of Cu/Al laminate metal composite fabricated by ultrasonic additive manufacturing (UAM) were investigated by electron backscattered diffraction, transmission electron microscopy and peeling tests. Results show that after the UAM process, Al foils have obvious shear texture or recrystallisation texture components in the region near the interface of Cu/Al, indicating that Al foils are prone to shear deformation during consolidation, which plays an essential role in the bonding formation of the two dissimilar metals. The rougher Cu foil surface produced by direct contact with sonotrode promotes more remarkable shear deformation of the mating Al foil near the interface during the subsequent consolidation pass, which obviously enhances the interfacial bonding strength.
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