Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.
Adam Hehr and Marcelo J. Dapino, "Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes," Proc. SPIE 9801, Industrial and Commercial Applications of Smart Structures Technologies 2016, 98010F (Presented at SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring: March 22, 2016; Published: 16 April 2016); https://doi.org/10.1117/12.2219570.
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