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Quantitative Evaluation of Bulk and Interface Microstructures in Al-3003 Alloy Builds Made by Very High Power Ultrasonic Additive Manufacturing

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Abstract

Ultrasonically consolidated 3003 aluminum alloy builds were prepared with constituent tapes by using a very high power ultrasonic additive manufacturing (UAM) process. Microstructures of interface and bulk regions were quantitatively characterized using the electron backscattered diffraction technique. The interface microstructure consists of equiaxed grains. The 〈111〉 crystallographic directions of these grains were aligned with the normal direction of the specimen, confirming a shear deformation mode at these regions. In addition, due to recrystallization, the density of low-angle grain boundaries also significantly decreased. In contrast, original elongated grains and partially recrystallized grains were observed in the bulk region of the tape. These elongated grains correspond to rolling texture components of face-centered-cubic materials. The preceding microstructure gradients are rationalized based on the accumulated thermomechanical cycles during processing.

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Notes

  1. In this document, tapes and foils are used interchangeably to allow for better readability.

  2. PHILIPS is a trademark of FEI Company, Hillsboro, OR.

  3. TSL OIM is a trademark of EDAX Inc., Draper, UT.

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Acknowledgments

The authors sincerely thank the Ohio Department of Development for funding this research work through the Third Frontier Wright Projects program. The support received from Dr. Karl Graff, Matt Short, Paul Boulware, and other colleagues from EWI is greatly appreciated. One of the authors (HTF) also thanks the Japan Society for Promotion of Science for providing the scholarship for this collaborative research.

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Authors and Affiliations

  1. Department of Material Science and Engineering, The Ohio State University, Columbus, OH, 43221, USA

    Hiromichi T. Fujii (Assistant Professor), M. R. Sriraman (Postdoctoral Fellow) & S. S. Babu (Associate Professor)

  2. Department of Materials Processing, Graduate School of Engineering, Tohoku University, Sendai, 908-8579, Japan

    Hiromichi T. Fujii (Assistant Professor)

Authors
  1. Hiromichi T. Fujii
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  2. M. R. Sriraman
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  3. S. S. Babu
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Correspondence to Hiromichi T. Fujii.

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Manuscript submitted February 8, 2011.

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Fujii, H.T., Sriraman, M.R. & Babu, S.S. Quantitative Evaluation of Bulk and Interface Microstructures in Al-3003 Alloy Builds Made by Very High Power Ultrasonic Additive Manufacturing. Metall Mater Trans A 42, 4045–4055 (2011). https://doi.org/10.1007/s11661-011-0805-x

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