A fabrication methodology for dual-material engineering structures using ultrasonic additive manufacturing
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The capabilities of additive manufacturing technologies to fabricate multi-material structures have been investigated in many studies. However, only a few of the technologies have been used to fabricate products for direct application. The full development of the capability will enable the fabrication of innovative engineering structures consisting of function-specific material members that cannot be realized using conventional methods. In this work, a methodology for fabricating dual-material engineering structures using ultrasonic additive manufacturing (UAM) was developed. An example structure consisting of members designed to carry tension and compression loads were fabricated using composite materials and Al 3003 matrix material respectively. MetPreg®/Al 3003 and Ti/Al 3003 composite materials were respectively used as tension members in two different structure samples. Single-material copies of the dual-material structures were fabricated using Al 3003 for load-carrying capability comparison. The results of the load tests carried out shows that the dual-material structures could withstand much higher loads than similar structures entirely made of the matrix Al 3003 material. This is an indication that UAM can be effectively used to fabricate multi-material engineering structures.
KeywordsAdditive manufacturing Ultrasonic additive manufacturing UAM Ultrasonic consolidation UC Multi-material structures Dual-material structures
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