1. September 14, 2011 Additive Manufacturing Techniques for Dissimilar Materials - VHPUAM Josh George Applications Engineer, Ultrasonics Email: jgeorge@ewi.orgjgeorge@ewi.org Phone: 614.688.5057

2. Overview Highlight UAM process Very high-power UAM system status Current developments – UAM bonding, smart structures New VHP research platform

3. Ultrasonic Additive Manufacturing* … a new technology – UAM creates net-shape solid metal parts using: solid state ultrasonic metal welding and CNC contour milling * UAM – aka Ultrasonic Consolidation Rotating Transducer, Booster, Horn System TransducerBoosterHorn Dummy Booster Al Base Plate Anvil Al Tape

4. US vibrations from transducer Welded tape US vibrations of horn … a bit more detail US Weld US horn – has textured surface to grip tape

5. … detail … Laying of tapes side-by-side, then layer-by-layer to build a solid plate In practice, tapes are first laid side-by-side, and then built up layer- by-layer to build a solid metal plate Each tape layer staggered from one below so seams do not line up. In practice, there are no gaps between adjacent tapes

6. Current Machine Status Materials – High power ability to weld Cu, Ni, stainless steel Part Size – Working envelope of 6- × 6- × 3-feet tall Speed – Welding speeds up to 400 in./minute with integrated CNC machining at up to 600 in./minute (example: 6x6x6 at 150 in./minute would take 33 hours) 9-kW Weld Module

7. Features Multi-axis, Speed Bump feature 9-kW Push – Pull Machining center with automatic tool changer Tape feed system accommodates up to 12-in. sheet

8. Process, Operation CAD Model Machine Code Fabrication

9. Example Products Rapid Prototyping Thermal Management Metal Matrix Composites Dissimilar Metal LaminatesEmbedded Electronics Complex Geometry Embedded Sensors Integrated Systems

10. Dissimilar Matrix Potential Process well suited to dissimilar metals and multi-material laminate –No liquid phase metallurgical incompatibilities Multiple metal foils can be combined Fiberoptic, B, and SiC fibers can be embedded without deleterious reactions with Al matrix Cu Al SiC fiber Material pair proven for ultrasonic welding Material pair tested for ultrasonic spot weld 10

11. UAM Bonding Extensive metallurgy studies; e.g., work with 3003 – evidence of recrystallization as bonding mechanism (a) and (b); heat buildup causes more extensive effect at top. Materials investigated: -110 Cu (>99.0% Cu), hard condition -3003 Al, H18 (strain-hardened) -6061 Al, H18 (strain-hardened) -304L SS (annealed) Original interface

12. Metallurgy Peak temperatures < 0.5T melt Extensive increase in interface stored energy Local formation of nano-grain colonies. Plastic-flow morphology 12 100 µm Bulk Tape Bond Area OIM SEM

13. Smart Materials, Structures Early embedding observations Has led development of Adaptive Metal Matrix SMA Composites 0.003-in.-Diameter NiTi Wire (400×) 381-μm-Diameter NiTi Wire 100 μm 4- × 100-μm-Diameter NiTi Wires 2- × 76-μm-Diameter NiTi Wires 1000 μm 100 μm 300 μm 254-μm-Thick NiTi Ribbon

14. Aluminum alloys have a high CTE (25.1 ppm/ o C) Thermally induced contraction of embedded NiTi can offset the thermal strain of the Al matrix NiTi/Al composites could maintain dimensional tolerances over an expanded temperature range Strain vs. Temperature for Sample 3 Application – Dimensionally Stable NiTi/Al Composites

15. Next Steps New Commercial Entity to Commercialize Fabrisonic LLC Based in Columbus, OH Selling Machines and UAM Parts University/Lab User Group Stimulate further research in UAM

16. Research Platform Specifications 2500-lb load 4.5- or 9-kW power 20 ×12 × 6 in. 200 ipm Available Fall 2011

17. Questions? Josh George Applications Engineer, Ultrasonics E-mail: jgeorge@ewi.orgjgeorge@ewi.org Phone: 614.688.5057