Junction growth in ultrasonic spot welding and ultrasonic additive manufacturing

Ward, Austin A.; Zhang, Yibing; Cordero, Zachary C.

doi:10.1016/j.actamat.2018.07.058

Cited by 42 publications

(36 citation statements)

References 71 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Metallurgical bonds between layers are achieved ultrasonically without generating molten metal at the interface [3], and this allows for a wide range of similar and dissimilar materials to be deposited. Also, UAM has a higher deposition rate as compared to other AM processes because of the lower heat input per deposited volume and faster heat dissipation [3,25]. Due to the solidstate bonding in UAM, residual stresses and distortions are significantly reduced compared to direct metal deposition, which involves liquid-solid transformation.…”

Section: Uam Versus Other Am Technologiesmentioning

confidence: 99%

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Gujba

Medraj

2020

Advances in Materials Science and Engineering

View full text Add to dashboard Cite

Additive manufacturing (AM) for fabricating 3D metallic parts has recently received considerable attention. Among the emerging AM technologies is ultrasonic additive manufacturing (UAM) or ultrasonic consolidation (UC), which uses ultrasonic vibrations to bond similar or dissimilar materials to produce 3D builds. This technology has several competitive advantages over other AM technologies, which includes fabrication of dissimilar materials and complex shapes, higher deposition rate, and fabrication at lower temperatures, which results in no material transformation during processing. Although UAM process optimization and microstructure have been reported in the literature, there is still lack of standardized and satisfactory understanding of the mechanical properties of UAM builds. This could be attributed to structural defects associated with UAM processing. This article discusses the effects of UAM process parameters on the resulting microstructure and mechanical properties. Special attention is given to hardness, shear strength, tensile strength, fatigue, and creep measurements. Also, pull-out, push-out, and push-pin tests commonly employed to characterize bond quality and strength have been reviewed. Finally, current challenges and drawbacks of the process and potential applications have been addressed.

show abstract

Section: Uam Versus Other Am Technologiesmentioning

confidence: 99%

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Gujba

Medraj

2020

Advances in Materials Science and Engineering

View full text Add to dashboard Cite

show abstract

“…In ultrasonic spot welding and ultrasonic additive manufacturing, junction growth results from thermal softening of surface asperities due to frictional heating. [ 67 ] Similarly, the distinct consolidation behaviors of the temperature‐sensitive pure Cu material and the thermally stable CuTa alloy indicate that thermal softening controls junction growth during ultrasonic powder compaction.…”

Section: Mechanisms Of Junction Growth Jamming and Densificationmentioning

confidence: 99%

Thermally Activated Jamming in Ultrasonic Powder Compaction

et al. 2020

Self Cite

View full text Add to dashboard Cite

Herein, the role of thermal softening in ultrasonic powder compaction is assessed by comparing the densification behaviors of nominally pure Cu and a thermally stable CuTa alloy. These materials have similar thermal properties, but pure Cu softens at much lower temperatures than does the CuTa alloy. Using a specialized ultrasonic powder compaction setup, in situ measurements of relative density, sonotrode power consumption, and temperature are collected, which together provide a time‐dependent geometric hardening parameter that reflects the structure of the compact. The geometric hardening data for the pure Cu powder reveal three distinct stages of densification: an initial particle rearrangement stage; a jamming transition where strong junctions develop between particles; and a final stage characterized by compatible plastic deformation. By contrast, the geometric hardening data for the thermally stable CuTa powder show that it remains a weak fluidized granular medium, despite experiencing higher normal pressures, oscillation amplitudes, and temperatures. The contrasting behaviors of the Cu and the CuTa powders suggest that a thermally activated jamming transition drives interparticle junction growth and densification in ultrasonic powder compaction.

show abstract

“…Ultrasonic welding technology is continuously expanding its usage range. It has been applied to additive manufacturing (AM) technology, which is in recent demand [17,18]. Wu [19] fabricated Ni-based bulk metallic glasses using ultrasonic welding technology.…”

Section: Introductionmentioning

confidence: 99%

Analysis of welding properties using various horn-tip patterns in the ultrasonic metal welding process

Kim

2020

Mechanics & Industry

View full text Add to dashboard Cite

The present study was conducted to investigate how the characteristics of welds are affected by the horn-tip pattern shape, in order to assess how to efficiently transfer the vibration energy to a base material through the horn. Energy transfer was evaluated using the indentation marks. The experiment was carried out with aluminum and copper by combining the conditions from four horn-tip patterns, six pressure values, and ten welding time values. The aspect ratio of the indentation marks on the weld surfaces was measured. The effects of the applied pressure, welding time, and horn-tip pattern shape on the aspect ratio were analyzed, and it was found that the horn-tip pattern shape affects the aspect ratio significantly. The aspect ratio was suggested as an analytical reference, and its correlations with the shear strength and the hardness of the welds were verified. In addition, the experiment performed with aluminum and copper, which have different mechanical properties, under the same welding conditions showed that the aspect ratio was dependent on the mechanical properties of the materials. In conclusion, as the density of the horn-tip pattern is decreased, less of the vibration energy was lost, increasing the strength of the welds. Experimental results showed that shear strength of copper was nearly 400 N when the aspect ratio was close to the value of 1. The highest peak of horn-tip pattern forms the lowest aspect ratio of the indentation mark, which can be indicated that the decrease of the aspect ratio effect to the improvement of welds strength. Aspect ratio of horn-tip pattern D, which dimensions are pitch 1.5 mm, height 0.75 mm and stub tooth 0.7 mm was closely to the value of 1 compared to the other patterns.

show abstract

Junction growth in ultrasonic spot welding and ultrasonic additive manufacturing

Cited by 42 publications

References 71 publications

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Thermally Activated Jamming in Ultrasonic Powder Compaction

Analysis of welding properties using various horn-tip patterns in the ultrasonic metal welding process

Contact Info

Product

Resources

About