Engineering Commons^™

Fabrication Of Multi-Material Structures Using Ultrasonic Consolidation And Laser-Engineered Net Shaping, John Olorunshola Obielodan

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

This research explores the use of two additive manufacturing processes for the fabrication of multi-material structures. Ultrasonic consolidation (UC) and laser- engineered net shaping (LENS) processes were used for parallel systematic investigations of the process parameters and methodologies for the development of multi-material structures.

The UC process uses ultrasonic energy at low temperature to bond metallic foils. A wide range of metallic materials including nickel; titanium; copper; molybdenum; tantalum; MetPreg®; silver; stainless steel; and aluminum alloys 1100, 3003, and 6061 were bonded in different combinations. Material domains are inherently discrete in ultrasonically consolidated structures. The mechanical properties of some of …

Support Materials Development And Integration For Ultrasonic Consolidation, Matthew L. Swank

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Support materials play a vital role across the entire field of additive manufacturing (AM) technologies. They are essential to provide the ability to create complex structures and features using AM. Successful implementation of support materials in ultrasonic consolidation (UC) will provide a vast opportunity for improvement of geometric complexity. Experimentation was performed to evaluate suitable support materials and their effectiveness within UC. Additionally a fused deposition modeling (FDM) system was integrated into the UC build environment to create an automated support deposition system. Finally several unique structures were built using support materials to demonstrate the improved geometric capability and to …

A Study On Stainless Steel 316l Annealed Ultrasonic Consolidation And Linear Welding Density Estimation, Raelvim Gonzalez

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Ultrasonic Consolidation of stainless steel structures is being investigated for potential applications. This study investigates the suitability of Stainless Steel 316L annealed (SS316L annealed) as a building material for Ultrasonic Consolidation (UC), including research on Linear Welding Density (LWD) estimation on micrographs of samples. Experiment results are presented that include the effect of UC process parameters on SS316L annealed UC, optimum levels of these parameters, and bond quality of ultrasonically consolidated SS316L annealed structures in terms of LWD. In support to these efforts, a Measurement System Analysis for LWD assessment has been performed, and a new instrument for LWD measurement …