Project Leader: Marcelo Dapino (OSU); Project Mentor: Ryan Hahnlen (Honda R&D) Project #51: Ultrasonic Additive Manufacturing for Automotive Structures Purpose: Enable lightweight vehicle structures via UAM Research Objectives: • Understand the cause for the knockoff in x- tensile (in-plane) strength resulting from the UAM process • Develop weld parameters that can reduce or eliminate the knockoff DIC Testing and Modeling: • Digital image correlation (DIC) used to measure 2D and 3D strain fields • Permits local and global measurements Methodology: • Investigate process- property relationships through Design of Experiments study • Prior pilot study focused on feasibility of welds • DOE study focused on x- tensile testing • FEA models developed to guide the experiments and assists with data analysis • 3D printing technology based on ultrasonic metal welding • Low-temperature process • Dissimilar metal parts and integrated structures Ultrasonic welding system with rolling horn welds metal tape to base plate Periodic machining shapes part and maintains uniform welding surface Horn Transducer Metal Base Plate Metal Tape Transducer Successive application of metal tape builds part Vibration Down Force Ultrasonic Additive Manufacturing:
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Project Leader: Marcelo Dapino (OSU); Project Mentor: Ryan Hahnlen (Honda R&D)
Project #51: Ultrasonic Additive Manufacturing for Automotive Structures
Purpose: Enable lightweight vehicle structures via UAM Research Objectives: • Understand the cause
for the knockoff in x-tensile (in-plane) strength resulting from the UAM process
• Develop weld parameters that can reduce or eliminate the knockoff
DIC Testing and Modeling:
• Digital image correlation (DIC) used to measure 2D and 3D strain fields
• Permits local and global measurements
Methodology:
• Investigate process-property relationships through Design of Experiments study
• Prior pilot study focused on feasibility of welds
• DOE study focused on x-tensile testing
• FEA models developed to guide the experiments and assists with data analysis
• 3D printing technology based on ultrasonic metal welding
• Low-temperature process • Dissimilar metal parts and
integrated structures
Ultrasonic welding system with rolling horn welds metal tape to base plate
Periodic machining shapes part and maintains uniform welding surface
Horn Transducer
Metal Base Plate Metal Tape
Transducer
Successive application of metal tape builds part
Vibration
Down Force
Ultrasonic Additive Manufacturing:
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