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Selective Reinforcement of Aerospace Structures Using Ultrasonic Additive Manufacturing

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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.

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Notes

  1. The foil is produced by cold rolling annealed 6061 billet to the final thickness (H18 condition).

  2. Quantity from matweb.com.

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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.

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Authors and Affiliations

  1. Fabrisonic LLC, Columbus, OH, 43221, USA

    Adam Hehr, Justin Wenning & Mark Norfolk

  2. Sheridan Solutions LLC, Saline, MI, 48176, USA

    John Sheridan

  3. NASA Langley Research Center, Hampton, VA, 23681, USA

    John. A. Newman & Marcia Domack

Authors
  1. Adam Hehr
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  2. Justin Wenning
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  3. Mark Norfolk
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  4. John Sheridan
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  5. John. A. Newman
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  6. Marcia Domack
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Correspondence to Adam Hehr.

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Hehr, A., Wenning, J., Norfolk, M. et al. Selective Reinforcement of Aerospace Structures Using Ultrasonic Additive Manufacturing. J. of Materi Eng and Perform 28, 633–640 (2019). https://doi.org/10.1007/s11665-018-3614-1

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  • DOI: https://doi.org/10.1007/s11665-018-3614-1

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