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Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures

Published online by Cambridge University Press:  14 July 2014

Paul J. Wolcott ,
Adam Hehr  and
Marcelo J. Dapino
Paul J. Wolcott
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
Adam Hehr
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
Marcelo J. Dapino*
Affiliation:
Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus 43210
*
a)Address all correspondence to this author. e-mail: [email protected]
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Abstract

Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process that combines additive joining of thin metal tapes and subtractive computer numerical control milling operations to generate near-net shape metallic parts. We conducted a design of experiments study with the goal to optimize UAM process parameters for aluminum 6061. Weld force, weld speed, amplitude, and temperature were varied based on a Taguchi L18 experimental design matrix and tested for mechanical strength using a shear test and a comparative push-pin test. Statistical methods including analysis of variance (ANOVA), mean effects plots, and interaction effects plots were conducted to determine optimal process parameters. Results indicate that weld amplitudes of 32.76 µm and weld speeds of 84.6 mm/s yield maximum mechanical strength while temperature and force are statistically insignificant for the parameter levels tested. Annealing of cold-worked foil stock produces a 13% strength increase for UAM samples over homogeneous annealed material.

Keywords

Alcompositestrength
Type
Articles
Information
Journal of Materials Research , Volume 29 , Issue 17: Focus Issue: The Materials Science of Additive Manufacturing , 14 September 2014 , pp. 2055 - 2065
Copyright
Copyright © Materials Research Society 2014 

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