Hostname: page-component-8448b6f56d-jr42d Total loading time: 0 Render date: 2024-04-20T11:06:24.440Z Has data issue: false hasContentIssue false
  • English
  • Français

Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

Published online by Cambridge University Press:  14 July 2014

Paul J. Wolcott ,
Adam Hehr  and
Marcelo J. Dapino
Paul J. Wolcott
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
Adam Hehr
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
Marcelo J. Dapino*
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
*
a)Address all correspondence to this author. e-mail: dapino.1@osu.edu
Get access

Abstract

Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process that combines additive joining of thin metal tapes and subtractive computer numerical control milling operations to generate near-net shape metallic parts. We conducted a design of experiments study with the goal to optimize UAM process parameters for aluminum 6061. Weld force, weld speed, amplitude, and temperature were varied based on a Taguchi L18 experimental design matrix and tested for mechanical strength using a shear test and a comparative push-pin test. Statistical methods including analysis of variance (ANOVA), mean effects plots, and interaction effects plots were conducted to determine optimal process parameters. Results indicate that weld amplitudes of 32.76 µm and weld speeds of 84.6 mm/s yield maximum mechanical strength while temperature and force are statistically insignificant for the parameter levels tested. Annealing of cold-worked foil stock produces a 13% strength increase for UAM samples over homogeneous annealed material.

Keywords

Alcompositestrength
Type
Articles
Information
Journal of Materials Research , Volume 29 , Issue 17: Focus Issue: The Materials Science of Additive Manufacturing , 14 September 2014 , pp. 2055 - 2065
Copyright
Copyright © Materials Research Society 2014 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Graff, K.: New Developments in Advanced Welding (Woodhead Publishing Limited, Cambridge, UK, 2005).Google Scholar
White, D.: Ultrasonic consolidation of aluminum tooling. Adv. Mater. Processes 161(1), 64–65 (2003).Google Scholar
Wolcott, P.J., Hehr, A., and Dapino, M.J.: Optimal welding parameters for very high power ultrasonic additive manufacturing of smart structures with aluminum 6061 matrix. In Proceedings of SPIE Smart Structures and Materials & Nondestructive Evaluation and Health Monitoring, San Diego, 2014.Google Scholar
Kong, C. and Soar, R.: Fabrication of metal-matrix composites and adaptive composites using ultrasonic consolidation process. Mater. Sci. Eng., A 412(1–2), 12–18 (2005).CrossRefGoogle Scholar
Kong, C., Soar, R., and Dickens, P.: Optimum process parameters for ultrasonic consolidation of 3003 aluminum. J. Mater. Process. Technol. 146(2), 181–187 (2004).CrossRefGoogle Scholar
Hopkins, C.H., Dapino, M.J., and Fernandez, S.A.: Statistical characterization of ultrasonic additive manufacturing Ti/Al composites. J. Eng. Mater. Technol. 132, 041006-1–041006-9 (2010).Google Scholar
Hopkins, C.H., Wolcott, P.J., Dapino, M.J., Truog, A.G., Babu, S.S., and Fernandez, S.A.: Optimizing ultrasonic additive manufactured Al 3003 properties with statistical modeling. J. Eng. Mater. Technol. 134(1), 011004-1–011004-10 (2012).CrossRefGoogle Scholar
[Online]. Available: uam.engineering.osu.edu.Google Scholar
ASM-International: Properties of Wrought Aluminum Alloys (ASM International, 2, 2010).Google Scholar
Zhang, C., Deceuster, A., and Li, L.: A method for bond strength evaluation for laminated structures with application to ultrasonic consolidation. J. Mater. Eng. Perform. 18(8), 1124–1132 (2009).CrossRefGoogle Scholar
Truog, A.G.: Master's Thesis: Bond Improvement of Al/Cu Joints Created by Very High Power Ultrasonic Additive Manufacturing (OSU's Graduate Program in Welding Engineering, Columbus, OH, 2012).Google Scholar
Dean, A. and Voss, D.: Design and Analysis of Experiments (Springer, New York, NY, 1999).Google Scholar
Davis, J.R.: Aluminum and Aluminum Alloys (ASM International, Materials Park, OH, 1993).Google Scholar