Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

Sridharan, Niyanth; Gussev, Maxim; Seibert, Rachel; Parish, Chad; Norfolk, Mark; Terrani, Kurt; Babu, Sudarsanam Suresh

doi:10.1016/j.actamat.2016.06.048

Title: Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

Journal Article · Thu Sep 01 00:00:00 EDT 2016 · Acta Materialia

DOI:https://doi.org/10.1016/j.actamat.2016.06.048· OSTI ID:1360032

Sridharan, Niyanth; Gussev, Maxim; Seibert, Rachel; Parish, Chad; Norfolk, Mark; Terrani, Kurt; Babu, Sudarsanam Suresh

Ultrasonic additive manufacturing (UAM) is a solid-state process, which uses ultrasonic vibrations at 20 kHz along with mechanized tape layering and intermittent milling operation, to build fully functional three-dimensional parts. In the literature, UAM builds made with low power (1.5 kW) exhibited poor tensile properties in Z-direction, i.e., normal to the interfaces. This reduction in properties is often attributed to the lack of bonding at faying interfaces. The generality of this conclusion is evaluated further in 6061 aluminum alloy builds made with very high power UAM (9 kW). Tensile deformation behavior along X and Z directions were evaluated with small-scale in-situ mechanical testing equipped with high-resolution digital image correlation, as well as, multi-scale characterization of builds. Interestingly, even with complete metallurgical bonding across the interfaces without any discernable voids, poor Z-direction properties were observed. This reduction is correlated to coalescence of pre-existing shear bands at interfaces into micro voids, leading to strain localization and spontaneous failure on tensile loading.

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Research Organization:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). High Temperature Materials Lab. (HTML); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Nuclear Science User Facility (NSUF)

Sponsoring Organization:: USDOE Office of Nuclear Energy (NE); USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1360032

Alternate ID(s):: OSTI ID: 1358710

Journal Information:: Acta Materialia, Vol. 117, Issue C; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 70 works

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A Survey of Modeling of Lattice Structures Fabricated by Additive Manufacturing Dong, Guoying; Tang, Yunlong; Zhao, Yaoyao Fiona Journal of Mechanical Design, Vol. 139, Issue 10 https://doi.org/10.1115/1.4037305	journal	August 2017
Perspective of additive manufacturing for metamaterials development Wu, Xin; Su, Yutai; Shi, Jing Smart Materials and Structures, Vol. 28, Issue 9 https://doi.org/10.1088/1361-665x/ab2eb6	journal	August 2019
Mechanical properties and microstructure evolution of dissimilar Mg and Al alloys welded using ultrasonic spot welding Li, Mingfeng; Zhu, Zhengqiang; Xiao, Qiankun Materials Research Express, Vol. 6, Issue 8 https://doi.org/10.1088/2053-1591/ab2010	journal	May 2019
On the potential mechanisms of β to α′ + β decomposition in two phase titanium alloys during additive manufacturing: a combined transmission Kikuchi diffraction and 3D atom probe study Sridharan, Niyanth; Chen, Yimeng; Nandwana, Peeyush Journal of Materials Science, Vol. 55, Issue 4 https://doi.org/10.1007/s10853-019-03984-w	journal	September 2019
Additive Manufacturing of Metallic Materials: A Review Zhang, Yi; Wu, Linmin; Guo, Xingye Journal of Materials Engineering and Performance, Vol. 27, Issue 1 https://doi.org/10.1007/s11665-017-2747-y	journal	May 2017
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