Elastic constants of Ultrasonic Additive Manufactured Al 3003-H18.

Ultrasonic Additive Manufacturing (UAM), also known as Ultrasonic Consolidation (UC), is a layered manufacturing process in which thin metal foils are ultrasonically bonded to a previously bonded foil substrate to create a net part. Optimization of process variables (amplitude, normal load and velocity) is done to minimize voids along the bonded interfaces. This work pertains to the evaluation of bonds in UAM builds through ultrasonic testing of a build's elastic constants. Results from ultrasonic testing on UAM parts indicate orthotropic material symmetry and a reduction of up to 48% in elastic constant values compared to a control sample. The reduction in elastic constant values is attributed to interfacial voids. In addition, the elastic constants in the plane of the Al foils have nearly the same value, while the constants normal to the foil direction have much different values. In contrast, measurements from builds made with Very High Power Ultrasonic Additive Manufacturing (VHP UAM) show a drastic improvement in elastic properties, approaching values similar to that of bulk aluminum.