Joining of carbon fiber and aluminum using ultrasonic additive manufacturing (UAM)

Guo, Hongqi; Gingerich, M. Bryant; Headings, Leon M.; Hahnlen, Ryan; Dapino, Marcelo J.

doi:10.1016/j.compstruct.2018.10.004

Cited by 46 publications

(21 citation statements)

References 18 publications

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“…[39]. This process bounds metallic sheets together using an ultrasonic welding operation [40]. In this process, an additional machining operation, which is controlled by Computer Numerical Control (CNC), is required to remove the unbounded material [40].…”

Section: Powder Bed Fusion (Pbf)mentioning

confidence: 99%

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

et al. 2021

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In recent years, Additive Manufacturing (AM), also called 3D printing, has been expanding into several industrial sectors due to the technology providing opportunities in terms of improved functionality, productivity, and competitiveness. While metal AM technologies have almost unlimited potential, and the range of applications has increased in recent years, industries have faced challenges in the adoption of these technologies and coping with a turbulent market. Despite the extensive work that has been completed on the properties of metal AM materials, there is still a need of a robust understanding of processes, challenges, application-specific needs, and considerations associated with these technologies. Therefore, the goal of this study is to present a comprehensive review of the most common metal AM technologies, an exploration of metal AM advancements, and industrial applications for the different AM technologies across various industry sectors. This study also outlines current limitations and challenges, which prevent industries to fully benefit from the metal AM opportunities, including production volume, standards compliance, post processing, product quality, maintenance, and materials range. Overall, this paper provides a survey as the benchmark for future industrial applications and research and development projects, in order to assist industries in selecting a suitable AM technology for their application.

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Section: Powder Bed Fusion (Pbf)mentioning

confidence: 99%

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

et al. 2021

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“…The main difference is that the FSAM is a hybrid additive/subtractive process that produces microstructures with cyclic variations [141,142], while in The low operation temperature and the plastic flow of metals provide the opportunity to embed and/or encapsulate various electronic devices in to the metal matrix through the UAM process. Smart material structures could be printed by embedding fibres, conductor, dielectric, and nano-fibres of NiTi shape memory alloy into a metal matrix [133]. Carbon fibres [134], fibre Bragg grating (FBG) [135], polymer-coated and uncoated optical fibres [136], metal-coated optical fibres [137], and NiTi shape memory alloy fibres [138,139] could be successfully embedded into Al matrix with sufficient bond strength in the welded interfaces of the metal foils while retaining their functionality.…”

Section: Friction Stir Additive Manufacturing (Fsam)mentioning

confidence: 99%

Beamless Metal Additive Manufacturing

2020

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The propensity to manufacture functional and geometrically sophisticated parts from a wide range of metals provides the metal additive manufacturing (AM) processes superior advantages over traditional methods. The field of metal AM is currently dominated by beam-based technologies such as selective laser sintering (SLM) or electron beam melting (EBM) which have some limitations such as high production cost, residual stress and anisotropic mechanical properties induced by melting of metal powders followed by rapid solidification. So, there exist a significant gap between industrial production requirements and the qualities offered by well-established beam-based AM technologies. Therefore, beamless metal AM techniques (known as non-beam metal AM) have gained increasing attention in recent years as they have been found to be able to fill the gap and bring new possibilities. There exist a number of beamless processes with distinctively various characteristics that are either under development or already available on the market. Since this is a very promising field and there is currently no high-quality review on this topic yet, this paper aims to review the key beamless processes and their latest developments.

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“…At the same time, specific application spaces are gaining a strong foothold through refinement. Some of these areas are dissimilar metal/material joining (Sridharan, et al , 2017; Hehr et al , 2018; Deng et al , 2018; Guo et al , 2019), integrating fiber optic strain sensors into metal (Saheb and Mekid, 2015; Hehr et al , 2017; Hehr et al , 2018;), and manufacturing heat exchanger devices (Norfolk and Johnson, 2015; Anderson et al , 2017; Hehr et al , 2018). These foothold areas are shown in Figure 14.…”

Section: Low-power Uammentioning

confidence: 99%

A comprehensive review of ultrasonic additive manufacturing

Hehr¹,

Norfolk²

2019

RPJ

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Purpose This paper aims to comprehensively review ultrasonic additive manufacturing (UAM) process history, technology advancements, application areas and research areas. UAM, a hybrid 3D metal printing technology, uses ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. No melting occurs in the process – it is a solid-state 3D metal printing technology. Design/methodology/approach The paper is formatted chronologically to help readers better distinguish advancements and changes in the UAM process through the years. Contributions and advancements are summarized by academic or research institution following this chronological format. Findings This paper summarizes key physics of the process, characterization methods, mechanical properties, past and active research areas, process limitations and application areas. Originality/value This paper reviews the UAM process for the first time.

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Joining of carbon fiber and aluminum using ultrasonic additive manufacturing (UAM)

Cited by 46 publications

References 18 publications

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

Beamless Metal Additive Manufacturing

A comprehensive review of ultrasonic additive manufacturing

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