ADVANCED MATERIALS & PROCESSES | APRIL 2023 22 combinations. The high-power ultrasonic weld head (horn) allows larger areas to be welded, stronger alloy capability, and higher productivity than other thin film joining techniques. One example is the welding of foils to busbars (Fig. 4). UAM allows the joining of copper to copper, aluminum to aluminum, and copper to aluminum. The low-temperature process achieves a high-quality bond without generating high temperatures that might affect adjacent electronics. Further, UAM is adaptable to high-volume automated machine tooling with production rates exceeding 20 million parts per year. NEW APPLICATIONS The Fabrisonic team continues to find new applications for UAM technology. Here are some recent examples. Combining 3D printing and traditional manufacturing processes. Traditional manufacturing operations are optimized to deliver the lowest possible price for each manufacturing method. If a part has been designed to take full advantage of 3D printing, every feature in that part may require a printer. However, most parts have only one or two features that require 3D printing. For those cases, a hybrid manufacturing method enables lower cost per part. This combination involves using traditional manufacturing for the main body and AM for the special features. Employing UAM as another process in a manufacturing line can optimize product performance and manufacturing throughput while reducing cost per part. Printing in space. Both govern- ment and commercial entities are developing tools for welding in space to repair existing structures and construct new and larger systems. UAM is optimal for welding in zero gravity and in a vacuum. Because the metal (feedstock) remains solid, there are no components or feedstock in a liquid or powder state. Power consumption is lower, and UAM is capable of welding dissimilar metals in one operation. Fabrisonic is currently testing UAM systems in a vacuum chamber, preparing for future deployment in space. Bulk metallic glasses. Historically, difficulties in bonding amorphous metals, also known as bulk metallic glasses (BMGs), have meant that they could only be added to a structure using relatively weak methods such as adhesive bonding. UAM forms metallic bonds near room temperature, allowing the preservation of amorphous structures while gaining the strength inherent in a true metallic bond. One issue with using a BMG can be its relatively low ductility compared to similar crystalline metals. UAM can be used to interweave BMGs with other more ductile metals. By combining the properties of the BMG with the properties of other metals, engineers can enhance ductility and fracture toughness while keeping the desirable BMG traits such as strength and corrosion resistance. Originating out of a lab and now preparing for space, UAM shows a unique promise, unlike any other form of additive manufacturing. UAM has proven to deliver a unique set of highly desirable capabilities, which can be applied at the point of need. ~AM&P For more information: Mark Norfolk, president, Fabrisonic LLC, 7719 Graphics Way, Lewis Center, OH 43035, 380.227.1400, mnorfolk@fabrisonic.com, fabrisonic.com. Fig. 4 — (a) Macrograph of copper/stainless laminate; and (b) electrical busbars made of aluminum and copper. (a) (b) 2022 EMAA WINNERS Dawn White (center), senior staff scientist at Oak Ridge National Laboratory, and Mark Norfolk, president of Fabrisonic LLC, accept the ASM Engineering Materials Achievement Award (EMAA) from then ASM President Judith Todd, FASM, at IMAT 2022. Other awardees not shown are Matt Short, director of engineering and business development, ToolTex Inc., and Karl Graff, principal engineer, EWI (retired). The team was recognized for development and commercialization of ultrasonic additive manufacturing.
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