10 March 2014 Optimal welding parameters for very high power ultrasonic additive manufacturing of smart structures with aluminum 6061 matrix
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Abstract
Ultrasonic additive manufacturing (UAM) is a recent solid state manufacturing process that combines ad- ditive joining of thin metal tapes with subtractive milling operations to generate near net shape metallic parts. Due to the minimal heating during the process, UAM is a proven method of embedding Ni-Ti, Fe-Ga, and PVDF to create active metal matrix composites. Recently, advances in the UAM process utilizing 9 kW very high power (VHP) welding has improved bonding properties, enabling joining of high strength materials previously unweldable with 1 kW low power UAM. Consequently, a design of experiments study was conducted to optimize welding conditions for aluminum 6061 components. This understanding is critical in the design of UAM parts containing smart materials. Build parameters, including weld force, weld speed, amplitude, and temperature were varied based on a Taguchi experimental design matrix and tested for me- chanical strength. Optimal weld parameters were identi ed with statistical methods including a generalized linear model for analysis of variance (ANOVA), mean e ects plots, and interaction e ects plots.
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Paul J. Wolcott, Adam Hehr, Marcelo J. Dapino, "Optimal welding parameters for very high power ultrasonic additive manufacturing of smart structures with aluminum 6061 matrix", Proc. SPIE 9059, Industrial and Commercial Applications of Smart Structures Technologies 2014, 905908 (10 March 2014); doi: 10.1117/12.2046291; https://doi.org/10.1117/12.2046291
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