Monitoring and repair of defects in ultrasonic additive manufacturing

Nadimpalli, Venkata Karthik; Karthik, G.M.; Janakiram, G.D.; Nagy, Péter B.

doi:10.1007/s00170-020-05457-w

Cited by 24 publications

(6 citation statements)

References 34 publications

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“…[ 3 ] Thus, in most cases, the applied ultrasonic amplitude and normal force are excessive, which indicates the input energy is generally higher than the energy required for forming the metallurgical bonding. On the other hand, according to the previous studies, [ 28,29 ] the power consumption of bonding each layer decreases with the increasing build height, which is also not negligible. However, the output power of the UAM machine is fixed under certain processing conditions.…”

Section: Resultsmentioning

confidence: 83%

“…These two parts of the ultrasonic energy that overflowed from the metallurgical bonding process propagate through the build component directly to the bottom of the build component. Nadimpalli et al [ 29 ] developed an ultrasonic NDE system to monitor the UAM stack quality and the interlayer defects in the component. One of their primary work was to measure and monitor the quality of the base/build interface.…”

Section: Resultsmentioning

confidence: 99%

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Dynamic Recrystallization and Recovery in Very High‐Power Ultrasonic Additive Manufacturing

et al. 2020

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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 among layers are characterized using electron backscattered diffraction (EBSD). The results reveal that among the upper layers, recrystallization only occurs at very local interface regions due to the local shear deformation, while the bulk region of each layer still remains the starting microstructure unaffected. However, after this cyclic accumulating process, dynamic recovery (DRV) and dynamic recrystallization (DRX) are observed to take place in the bottom of the built samples. The evolution of microstructures and textures of the bottom layer is a function of input energy, which well explains the effect of ultrasonic energy on the microstructure evolution at the metallurgical bonding regions.

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Section: Resultsmentioning

confidence: 83%

Section: Resultsmentioning

confidence: 99%

Dynamic Recrystallization and Recovery in Very High‐Power Ultrasonic Additive Manufacturing

et al. 2020

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“…The solid-state AM system can produce optimal results as a primary bonding mechanism. The friction stir processing can be used as a repair tool (Nadimpalli et al, 2020). Despite the above challenges, UAM methods are being used in many industries because of producing near-net shape welded parts with minimum waste as opposed to other AM technologies and conventional machining such as CNC.…”

Section: Future Prospectsmentioning

confidence: 99%

“…The solid-state AM system can produce optimal results as a primary bonding mechanism. The friction stir processing can be used as a repair tool (Nadimpalli et al , 2020).…”

Section: Future Prospectsmentioning

confidence: 99%

Review of recent trends in ultrasonic additive manufacturing: current challenges and future prospects

Ishfaq

Abas

Kumar

et al. 2023

RPJ

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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.

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“…The first powder-bed fusion (PBF) process is selective laser sintering (SLS) developed by the DTM Corporation, USA, Fig. 1 Classification of metal additive manufacturing processes [8,[10][11][12][13][14][15][16]. Reproduced with permission from Elsevier in 1992 [21].…”

Section: Selective Laser Melting (Slm)mentioning

confidence: 99%

Heterogeneous Aspects of Additive Manufactured Metallic Parts: A Review

2021

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Metal additive manufacturing (MAM) is an emerging technology to produce complex end-use metallic parts. To adopt MAM for manufacturing numerous engineering parts used in critical applications, a thorough understanding of the relationship between the complex thermal cycles in MAM and the unique heterogeneous microstructures of MAM parts need to be established. This review article provides a comprehensive overview of the evolution of heterogeneous microstructures in MAM parts, including melt pool boundaries, heterogeneous grain structure, sub-grain cellular structure, matrix supersaturation, segregation, phase transformation, oxides formation, and texture. The evolution of residual stresses and the anisotropy in MAM parts and the post-MAM heat treatment effects on the microstructural evolution are also discussed. This review covers the microstructural aspects of most engineering materials in particular steels, high entropy alloys, aluminum alloys, titanium alloys, nickel-base superalloys, and copper alloys, with a primary focus on the parts manufactured using selective laser melting, direct energy deposition, and electron beam melting processes.

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Monitoring and repair of defects in ultrasonic additive manufacturing

Cited by 24 publications

References 34 publications

Dynamic Recrystallization and Recovery in Very High‐Power Ultrasonic Additive Manufacturing

Dynamic Recrystallization and Recovery in Very High‐Power Ultrasonic Additive Manufacturing

Review of recent trends in ultrasonic additive manufacturing: current challenges and future prospects

Heterogeneous Aspects of Additive Manufactured Metallic Parts: A Review

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