Advertisement

Journal of Materials Engineering and Performance

, Volume 28, Issue 2, pp 633–640 | Cite as

Selective Reinforcement of Aerospace Structures Using Ultrasonic Additive Manufacturing

  • Adam HehrEmail author
  • Justin Wenning
  • Mark Norfolk
  • John Sheridan
  • John. A. Newman
  • Marcia Domack
Article
  • 103 Downloads

Abstract

The combination of ultrasonic additive manufacturing (UAM) and metal matrix composite (MMC) materials enables novel and unique structures for the aerospace industry. This paper discusses tensile testing and modeling of MMC composites made with UAM for the first time. Composites built with 20, 34, and 45% MMC exhibited strengths near 430, 550, and 650 MPa, respectively. Complementary microscopy and CT scans are used to inform the modeling and testing effort. Modeling and testing show close agreement. Lastly, a non-standardized fatigue specimen is fabricated and tested to failure. The specimen began to crack near 500 k cycles and was resistant to failure (> 20 M cycles). On the other hand, a reference unreinforced specimen began to crack near 100 k cycles and failed near 180 k cycles.

Keywords

additive manufacturing aerospace aluminum dynamic mechanical metal matrix composite static mechanical structural ceramics 

Notes

Acknowledgments

The authors would like to acknowledge financial support from NASA’s SBIR Office, NNX16CL34C. The authors are grateful for the support of Dr. Jennifer Sietins, Army Research Labs, who provided the CT-scan analysis. Support from Brian Gordon at Touchstone is also appreciated.

References

  1. 1.
    R. Bucci, Advanced Metallic & Hybrid Structural Concepts, USAF Structural Integrity Program Conference, San Antonio, TX, 2006Google Scholar
  2. 2.
    G.L. Farley, Selective Reinforcement to Enhance the Structural Performance of Metallic Compression Panels, AIAA Structures, Structural Dynamics and Materials Conference, Palm Springs, CA, 2004Google Scholar
  3. 3.
    G.L. Farley, J.A. Newman, and M.A. James, Selective Reinforcment to Improve Fracture Toughness and Fatigue Crack Growth Resistance in Metallic Structures, AIAA Structures, Structural Dynamics and Materials Conference, Palm Springs, CA, 2004Google Scholar
  4. 4.
    G.L. Farley and B.R. Seshadri, Performance Enhancement Using Selective Reinforcement for Metallic Single- and Multi-pin Loaded Holes, AIAA Structures, Structural Dynamics and Materials Conference, Austin, TX, 2005Google Scholar
  5. 5.
    R.K. Bird, J.A. Alexa, P.L. Messick, M.S. Domack, and J.A. Wagner, Investigation of Methods for Selectively Reinforcing Aluminum and Aluminum-Lithium Materials, NASA Langley Research Center, Hampton, VA, 2013Google Scholar
  6. 6.
    C.V. Jutte, B.K. Stanford, C.D. Wieseman, and J.B. Moore, Aeroelastic Tailoring of the NASA Common Research Model via Novel Material and Structural Configurations, AIAA SciTech Conference, National Harbor, MD, 2014CrossRefGoogle Scholar
  7. 7.
    B. Stucker, J. Obielodan, A. Ceylan, and L. Murr, Multi-Material Bonding in Ultrasonic Consolidation, Rapid Prototyp. J., 2010, 16(3), p 180–188CrossRefGoogle Scholar
  8. 8.
    G. Janaki Ram, C. Robinson, Y. Yang, and B. Stucker, Use of Ultrasonic Consolidation for Fabrication of Multi-Material Structures, Rapid Prototyp. J., 2007, 13(4), p 226–235CrossRefGoogle Scholar
  9. 9.
    J. Obielodan and B. Stucker, Dual-Material Minimum Weight Structures Fabrication Using Ultrasonic Consolidation, Solid Freeform Fabrication Symposium, Austin, TX, 2010Google Scholar
  10. 10.
    J. Obielodan and B. Stucker, A fabrication Methodology for Dual-Material Engineering Structures Using Ultrasonic Additive Manufacturing, Int. J. Adv. Manuf. Technol., 2014, 70, p 277–284CrossRefGoogle Scholar
  11. 11.
    H. Deve and C. McCullough, Continuous-Fiber Reinforced Al Composites: A New Generation, JOM, 1995, 47(7), p 33–37CrossRefGoogle Scholar
  12. 12.
    V. Irick and B. Gordon, MetPreg Metallic Prepregs for the Composites Industry, SAMPE J., 2004, 40(2), p 8–15Google Scholar
  13. 13.
    D. White, Ultrasonic Consolidation of Aluminum Tooling, Adv. Mater. Process., 2003, 161(1), p 64–65Google Scholar
  14. 14.
    K. Graff, M. Short, and M. Norfolk, Very High Power Ultrasonic Additive Manufacturing (VHP UAM) for Advanced Materials, Solid Freeform Fabrication Symposium, Austin, TX, 2010Google Scholar
  15. 15.
    J. Sietins, Exploring Diffusion of Ultrasonically Consolidated Aluminum and Copper Films Through Scanning and Transmission Electron Microscopy, Ph.D. thesis, University of Delaware, 2014Google Scholar
  16. 16.
    ASTM, Standard Test Method for Tensile Properties of Fiber Reinforced Metal Matrix Composites, 2016. https://www.astm.org/Standards/D3552.htm
  17. 17.
    B.D. Agarwal, L.J. Broutman, and K. Chandrashekhara, Analysis and Performance of Fiber Composites, Wiley, Hoboken, 2006Google Scholar
  18. 18.
    P. Leser, Probabilistic Prognostics and Health Managment for Fatigue-crical Components using High-Fidelity Models, Ph.D. thesis, North Carolina State University, 2017Google Scholar

Copyright information

© ASM International 2018

Authors and Affiliations

  • Adam Hehr
    • 1
    Email author
  • Justin Wenning
    • 1
  • Mark Norfolk
    • 1
  • John Sheridan
    • 2
  • John. A. Newman
    • 3
  • Marcia Domack
    • 3
  1. 1.Fabrisonic LLCColumbusUSA
  2. 2.Sheridan Solutions LLCSalineUSA
  3. 3.NASA Langley Research CenterHamptonUSA

Personalised recommendations