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Engineering Science and Materials Commons

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2009

Ultrasonic Consolidation

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Full-Text Articles in Engineering Science and Materials

Dynamics Of Ultrasonic Consolidation, James Gibert Dec 2009

Dynamics Of Ultrasonic Consolidation, James Gibert

All Dissertations

Ultrasonic consolidation (UC) is a solid state rapid manufacturing process derived from ultrasonic welding of thin metal foils coupled with contour milling to achieve functional accurate components. The bonding of metal is accomplished by the local application of high frequency vibration energy under pressure producing a metallurgical bond without melting the base material. Its unique nature allows the design and fabrication of structural panels for satellites, production of injection molding tools, functionally graded structures, metal-matrix composites, embedded sensors, armor, and fiber embedded adaptive structures. It is commonly theorized that interfacial motion and friction at the bonding interface play a prominent ...


Dynamic Finite Element Simulation Of Ultrasonic Consolidation, Daniel Mccullough Aug 2009

Dynamic Finite Element Simulation Of Ultrasonic Consolidation, Daniel Mccullough

All Theses

Ultrasonic Consolidation (UC) is a promising solid state rapid manufacturing process that provides the ability to create functional, multilayered, and often geometrically complex parts. This thesis seeks to address one of the primary obstacles faced when using the process, namely the apparent build height limit encountered when using UC to construct high aspect ratio specimens. A fully transient, three dimensional Finite Element model is created to study the dynamic behavior of an ultrasonically consolidated part during the UC process. The model is used to find the cause of bond failure at the build height limit and a potential way to ...