On the Formability of Ultrasonic Additive Manufactured Al-Ti Laminated Composites
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LUMINUM is one of the most commonly available metals in the earth’s crust and is used in a variety of commercial applications due to its low density, high thermal conductivity, excellent corrosion resistance, and weldability properties. Titanium, on the other hand, is preferred where anti-corrosion and high strength is required.[1] Lightweight Al-Ti laminated metal composites (LMCs), combining the features of these two metals, exhibit unique properties such as high strength, stiffness, and toughness.[2,3] Therefore, LMCs have increasingly been considered for various applications in defense, aerospace, structural, and automotive applications.[4] In this regard, consolidated aluminum (AA1100) and titanium (CP-1) layers have found applications in light weighting of vehicles and mine blast mitigation.[5] From the economical point of view, the Ti-Al3Ti system is
_ IRFAN KAYA is with the Department of Mechanical Engineering, Faculty of Engineering, Anadolu University, 26555 Eskisehir, Turkey and also with the Department of Mechanical Engineering, Faculty of Engineering, Eskisehir Technical University, 26555 Eskisehir. Contact e-mail: [email protected] O¨MER NECATI CORA and DOGˇAN ACAR are with the Department of Mechanical Engineering, Karadeniz Technical University, 61080 Trabzon, Turkey. MUAMMER KOC¸ is with the Sustainable Development Division, College of Science & Engineering, Hamad bin Khalifa University (HBKU), Qatar Foundation (QF), Education City, Doha, Qatar. Manuscript submitted December 11, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS A
economically more attractive than monolithic Ti as Al is inexpensive compared to Ti.[6] Existing production methods of LMCs are diverse; including adhesive bonding, brazing, ultrasonic welding, or combinations. Ultrasonic additive manufacturing (UAM), also referred as to ultrasonic consolidation (UC), is a revolutionary technology where thin and dissimilar materials are bonded in solid state through the action of ultrasonic vibration energy with low energy consumption.[7,8] The technology, developed by Solidica, Inc. (now Fabrisonic, Inc., affiliated with Edison Welding Institute, Columbus, OH), uses ultrasonic vibration to bond metal foils into near net-shaped components.[9] The UAM process uses the power of high-frequency ultrasonic vibration at low amplitude (without the need for high temperatures or pressures) that provide friction leading to welding of thin and dissimilar metals layers.[10-12] The oxides and the contaminants on the surface of adjacent layers are broken up with high-power ultrasonic vibrations, and asperities are flattened through the shear vibration-induced frictional heat effect.[13-16] The atomically clean surfaces allow intimate metal to metal contact, and provide improved bonding strength (see Figure 1).[16-20] Extensive mechanical interlocking occurs in ultrasonic welding of two dissimilar metals. In addition, thermal and acoustic softening are also known to cause plastic deformation and bond formations.[21] For Al-Ti LMC, in particular, the soft
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