超声增材制造在航空航天领域的应用进展

doi:10.11896/cldb.21040295

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Abstract Ultrasonic additive manufacture is a kind of low-temperature and solid-state process, the principle of which isproducing metallurgical bonds under ultrasonic vibration between metal layers near room temperature. Melting does not appear in the process. Complex internal or external structures can be fabricated after combining the subtractive machining with the additive process. However, the bonding mechanisms between metal layers in ultrasonic additive manufacture are just now being elucidated, and the relationship between process parameters and interface microstructures and bonding qualities is still uncertain, which is prone to failure at interfaces. Besides, there are limited kinds of materials that can be applied in the ultrasonic additive manufacture process, which prevents its application in the aerospace field. To sum up, researches at home and abroad are mainly focused on the following four parts: (i) bonding mechanisms;(ii) process parameters optimization and modeling;(iii) bonding characteristics of dissimilar materials;(iv) support materials.
Previous studies show that bonds between metal layers are mainly resulted from the plastic deformation, while the crystal broken and dynamic fatigue failure around the interfaces in the process will result in the poor bonding quality. Experimental and simulation researches indicate that amplitudes, speed, downforce, and aspect ratio of deposited metal layers are main factors affecting the bonding qualities. Actual machining process can be better conducted by constructing the process windows for different materials. Studies of the microstructure characteristics at bonding interfaces between dissimilar materials show that better bonding qualities can be obtained between the FCC structure, i.e. titanic, aluminum, copper, stainless steel, et. al, while Al 1100 and Al 3003 are applied to non-FCC materials. The bonding strength of aluminum alloy embedded SiC fiber or NiTi shape memory wires will be largely influenced by the amplitudes, speed, downforce, substrate preheating temperature and directions of fibers in the matrix. As to support materials, those which are hard and cannot melt in the process are considered to lead to better bonding quality, such as lead-free solder. Meanwhile, exploration for the application of ultrasonic additive manufacturing process in aerospace are conducted. Typical cases including efficient heat exchanger, embedded electronic component and surface repair have been implemented.
This paper introduces the basic processes and principles of ultrasonic additive manufacturing process. The research statuses of this technology are reviewed subsequently, while its applications in the aerospace field are summarized. Future work or development trends of ultrasonic additive manufacture in aerospace are analyzed, which are intended to further extend applied realms of this technology.

Key words： ultrasonic additive manufacture composite low-temperature process aerospace

Published: Online: 2023-02-08

CLC number:

V261.92

Corresponding Authors: zsthu@tsinghua.edu.cn

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	LIU Ting
	ZHU Yu
	HU Xiao
	ZHANG Song

Cite this article:

LIU Ting,ZHU Yu,HU Xiao, et al. Advances in the Research of Ultrasonic Additive Manufacturing in Aerospace Field[J]. Materials Reports, 2023, 37(2): 21040295-8.

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http://www.mater-rep.com/EN/10.11896/cldb.21040295 OR http://www.mater-rep.com/EN/Y2023/V37/I2/21040295

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