Numerical modeling of mechanical properties of UAM reinforced aluminum hat sections for automotive applications

Ahn, Hyeong Sik; Gingerich, M. Bryant; Hahnlen, Ryan; Dapino, Marcelo J.; Pourboghrat, Farhang

doi:10.1007/s12289-020-01607-3

Cited by 6 publications

(1 citation statement)

References 17 publications

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“…However, this challenge still needs to be standardized (Schick et al , 2010). Understanding welded parts’ mechanical properties needs to be explored broadly (Ahn et al , 2021), and there should be some standard tests for mechanical properties and defects repairs. The solid-state AM system can produce optimal results as a primary bonding mechanism.…”

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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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

View full text Add to dashboard Cite

show abstract

Experimental characterization and finite element simulation of FDM 3D printed polymer composite tooling for sheet metal stamping

Athale

Park

Hahnlen

et al. 2022

Int J Adv Manuf Technol

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Environmental impact of process constrained topology optimization design on automotive component’ life

Borda,

La Rosa,

Filice

et al. 2023

Int J Mater Form

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The components’ lightweighting has been pursued, especially in the transport industry, for greenhouse gas reduction. Topology optimization, being able to allocate the material within a provided design space, is a mathematical method that can support the design of lightweight components, preserving, at the same time, their mechanical performances. In this paper, a standard shape of a component, specifically an automotive bracket, was topology optimized by estimating the impacts of the new designs from an eco-friendly point of view. A subtractive, an additive and a casting manufacturing process were considered as possible manufacturing routes achieving an optimized geometry of the component for each of them. The topology optimizations were performed considering each processes’ peculiarities, introduced as constraints. Same strength for a given set of loads and boundary conditions was the target of each analysis. The component’s lightening can be considered environmentally friendly just after assessing the impacts associated with all the stages of the product’ life cycle. Indeed, each phase of the product’ life cycle can be affected, differently, by the performed topology optimization taking into account the peculiarities of the employed manufacturing process. The overall considerations on the most environmentally safe strategies can, therefore, change according to the specificities of the optimized shapes. The topology optimization showed its utmost potentiality, from a sustainable point of view, if applied to additive manufacturing techniques for the advantages arisen by the capability to manufacture complex shapes benefiting also of reduction time process owing to less material to be deposited.

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Numerical modeling of mechanical properties of UAM reinforced aluminum hat sections for automotive applications

Cited by 6 publications

References 17 publications

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

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

Experimental characterization and finite element simulation of FDM 3D printed polymer composite tooling for sheet metal stamping

Environmental impact of process constrained topology optimization design on automotive component’ life

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