Abstract
The formation of smart, Metal Matrix Composite (MMC) structures through the use of solid-state Ultrasonic Additive Manufacturing (UAM) is currently hindered by the fragility of uncoated optical fibers under the required processing conditions. In this work, optical fibers equipped with metallic coatings were fully integrated into solid Aluminum matrices using processing parameter levels not previously possible. The mechanical performance of the resulting manufactured composite structure, as well as the functionality of the integrated fibers, was tested. Optical microscopy, Scanning Electron Microscopy (SEM) and Focused Ion Beam (FIB) analysis were used to characterize the interlaminar and fiber/matrix interfaces whilst mechanical peel testing was used to quantify bond strength. Via the integration of metallized optical fibers it was possible to increase the bond density by 20–22%, increase the composite mechanical strength by 12–29% and create a solid state bond between the metal matrix and fiber coating; whilst maintaining full fiber functionality.
Highlights
Ultrasonic Additive Manufacturing (UAM) is a solid state metal Additive Manufacturing (AM) process that utilizes ultrasonic oscillations to bond metal tapes layer by layer before using periodic Computer Numerical Controlled (CNC) machining to fabricate complex three-dimensional components [1].In UAM a rolling cylindrical horn, known as a sonotrode, applies the ultrasonic oscillations generated by an ultrasonic transducer to the thin metal tapes
At both the High parameter (HP) and lower parameter (LP) UAM processing parameters, the metal-coated optical fibers were capable of transmitting light with minimal power loss
The ability to encapsulate uncoated optical fibers within UAM metal matrices has previously been demonstrated to be limited to relatively low UAM energy parameters
Summary
Ultrasonic Additive Manufacturing (UAM) is a solid state metal Additive Manufacturing (AM) process that utilizes ultrasonic oscillations to bond metal tapes layer by layer before using periodic Computer Numerical Controlled (CNC) machining to fabricate complex three-dimensional components [1].In UAM a rolling cylindrical horn, known as a sonotrode, applies the ultrasonic oscillations generated by an ultrasonic transducer to the thin metal tapes (ca. thickness 50–200 lm). In UAM a rolling cylindrical horn, known as a sonotrode, applies the ultrasonic oscillations generated by an ultrasonic transducer to the thin metal tapes Ultrasonic oscillations and compressive normal forces applied through the sonotrode, interfacial stresses and intimate contact between mating foil surfaces are induced. This leads to disruption of typically stubborn oxide layers and induces both static and shear forces within the metallic foils. The strength and quality of the final part produced is directly related to several processing parameters controlled by the operator, including; normal force applied by the sonotrode The strength and quality of the final part produced is directly related to several processing parameters controlled by the operator, including; normal force applied by the sonotrode (ca. 500–2000 N), traverse speed of sonotrode (ca. 10–100 mm/s), amplitude of sonotrode oscillation
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