Effect of system compliance on weld power in ultrasonic additive manufacturing
ISSN: 1355-2546
Article publication date: 18 August 2021
Issue publication date: 22 October 2021
Abstract
Purpose
Ultrasonic additive manufacturing (UAM) is a solid-state joining technology used for three-dimensional printing of metal foilstock. The electrical power input to the ultrasonic welder is a key driver of part quality in UAM, but under the same process parameters, it can vary widely for different build geometries and material combinations because of mechanical compliance in the system. This study aims to model the relationship between UAM weld power and system compliance considering the workpiece (geometry and materials) and the fixture on which the build is fabricated.
Design/methodology/approach
Linear elastic finite element modeling and experimental modal analysis are used to characterize the system’s mechanical compliance, and linear system dynamics theory is used to understand the relationship between weld power and compliance. In-situ measurements of the weld power are presented for various build stiffnesses to compare model predictions with experiments.
Findings
Weld power in UAM is found to be largely determined by the mechanical compliance of the build and insensitive to foil material strength.
Originality/value
This is the first research paper to develop a predictive model relating UAM weld power and the mechanical compliance of the build over a range of foil combinations. This model is used to develop a tool to determine the process settings required to achieve a consistent weld power in builds with different stiffnesses.
Keywords
Acknowledgements
This material is based upon work supported by the National Science Foundation, CMMI Division Grant No. 1538275. G.V. was supported from a NSF Graduate Fellowship under Grant No. 1102690 and from the member organizations of the Smart Vehicle Concepts Center (www.SmartVehicleCenter.org), a National Science Foundation Industry/University Cooperative Research Center. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the National Science Foundation.
Citation
Venkatraman, G., Hehr, A., Headings, L.M. and Dapino, M.J. (2021), "Effect of system compliance on weld power in ultrasonic additive manufacturing", Rapid Prototyping Journal, Vol. 27 No. 9, pp. 1650-1663. https://doi.org/10.1108/RPJ-07-2020-0168
Publisher
:Emerald Publishing Limited
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