Ultrasonic additive manufacturing (UAM) is a solid-state fabrication technique that consists of bonding layered foils of similar and dissimilar metals.  Ultrasonic Additive Manufacturings an additive/ subtractive process combining ultrasonic welding with computer numerical control (CNC) milling. The process begins with a thin metal foil that is placed placement on sacrificial metal base plate that is bolted on an anvil that can be heated (180◦F). The foil is compressed under mod- erate pressure by a rolling ultrasonic horn, also known as the sonotrode, which vibrates nominally at a frequency of 20 kHz in a direction transverse to the rolling direction, with amplitudes on the order of 10 to 32 microns. One area of promising research in UAM is the development of embedded sensors. Embedding a sensor allows for real-time monitoring of the structure and embedding the sensor within the structure reduces potential damage to the sensor. Embedding sensors in metal-matrices poses a challenge due to issues with typical fabrication techniques, but with UAM the low process temperature allows for direct embedding of sensors without the need for protective layers around the typically sensitive devices. Previous research in UAM has embedded fiber optics, fiber Bragg gratings, and PVDF phases in aluminum matrices, However, these sensor devices are fragile, expensive, or require specialized equipment to monitor. A sensor technology that has not been used in UAM is triboelectric nanogenerators (TENGs). TENGs are useful because they are flexible, robust, inexpensive, easy to manufacture, and have a simple output measurement. 


Ultrasonic Additive Manufacturing of a Triboelectric Composite

Division / Sponsors: 
Aerospace Division

Paper Proceedings: https://asmedigitalcollection.asme.org/SMASIS/SMASIS2020/volume/84027

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