Effect of processing parameters on bond properties and microstructure evolution in ultrasonic additive manufacturing (UAM)

Wang, Zhenqiang; Diao, Mingxia; Guo, Chunhuan; Wang, Jiandong; Zhao, Chengzhi; Jiang, Fengchun

doi:10.1088/2053-1591/abe9d3

Cited by 3 publications

(2 citation statements)

References 46 publications

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“…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].…”

Section: Introductionmentioning

confidence: 99%

Interfacial texture and bonding strength of Cu/Al laminate metal composite fabricated by ultrasonic additive manufacturing

Zhou

Chen

Wang

et al. 2022

Science and Technology of Welding and Joining

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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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Section: Introductionmentioning

confidence: 99%

Interfacial texture and bonding strength of Cu/Al laminate metal composite fabricated by ultrasonic additive manufacturing

Zhou

Chen

Wang

et al. 2022

Science and Technology of Welding and Joining

Self Cite

View full text Add to dashboard Cite

show abstract

“…Ion-channeling contrast imaging using a focused ion beam (FIB) has also been conducted for Al 3003-H18 to discover thin bands of nanograins near the welder and the modification in the grain morphology is explained by the accumulative thermomechanical processes due to sequential bonding of foils [14]. Some studies such as [15] qualitatively analyzed SEM (scanning electron microscope) scans of UAM-ed Al 1100-O samples fabricated using different process parameters but neither a quantitative analysis to compare the samples nor any quantification of stored energy was conducted.…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on the Microstructure of Aluminum Alloys Made via Ultrasonic Additive Manufacturing

2022

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Ultrasonic additive manufacturing (UAM) has garnered significant interest in the aerospace and automotive industries for its structural lightweighting and multi-material joining capabilities. This paper details the investigation on the effect of process variables on the resultant microstructure of the built-up part using UAM for aluminum 6061. The degree of recrystallization is quantified, and an energy metric, defined using the Read–Shockley relationship, is used to build an energy map of the welded part. The total energy stored in the resultant weld interface microstructure is quantified as a fraction of the input and is found to be about 0.1%. The width, average grain size, and percentage of High Angle Grain Boundaries (% HAGB) were used to compare microstructures of builds prepared using different processing conditions. Welding subsequent weld layers was not found to affect the previous welded layers. The effect of vibration amplitude and travel speed on the as-built microstructure were investigated, and the width of the interface was found to more than double when the weld amplitude is increased from the threshold value for joining (23 μm) and then stabilize at higher weld amplitudes. A better understanding of the effect of processing parameters on as-welded microstructures will assist parameter selection for UAM.

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Joint Quality Assessment of Ultrasonic Metal Welded Parts by Fracture Surface Evaluation

Müller,

Zhao,

Schiebahn

et al. 2024

Metals

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In ultrasonic metal welding, low specific resistances and large joining surface cross-sections require the use of mechanical testing to quantify the joint quality. In this study, different quality features of ultrasonically welded joints made of pure copper sheet are investigated during the successive phases of joint formation. Two test series with different workpiece geometries are examined. It is shown that mechanical quality features such as shear and peel forces behave differently over the formation of the joint and are not transferable. As an alternative to these, laser scanning microscopy is used to record images of the fracture surface that describe the growth of the joint area during formation. The study finds that shear tensile force growth and joint area growth are non-linear and comparable, with optimized welds achieving joint areas of 30 mm2 out of 64 mm2 and 6 mm2 out of 16 mm2. Although overall quality increases with increasing welding time, the material strength in the joint zone decreases. Depending on the original rolling condition, between 43% and 59% of the original material strength can be identified as the joint strength. The automatic analysis of fracture images is a suitable alternative to mechanical testing for similar joints.

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Effect of processing parameters on bond properties and microstructure evolution in ultrasonic additive manufacturing (UAM)

Cited by 3 publications

References 46 publications

Interfacial texture and bonding strength of Cu/Al laminate metal composite fabricated by ultrasonic additive manufacturing

Interfacial texture and bonding strength of Cu/Al laminate metal composite fabricated by ultrasonic additive manufacturing

Effect of Process Parameters on the Microstructure of Aluminum Alloys Made via Ultrasonic Additive Manufacturing

Joint Quality Assessment of Ultrasonic Metal Welded Parts by Fracture Surface Evaluation

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