Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing
Abstract
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.
- Authors:
- Publication Date:
- Research Org.:
- 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 Org.:
- USDOE Office of Nuclear Energy (NE); USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- OSTI Identifier:
- 1360032
- Alternate Identifier(s):
- OSTI ID: 1358710
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Acta Materialia
- Additional Journal Information:
- Journal Volume: 117; Journal Issue: C; Journal ID: ISSN 1359-6454
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- Ultrasonic additive manufacturing; Electron Back Scatter Diffraction; Digital Image correlation; tensile tests
Citation Formats
Sridharan, Niyanth, Gussev, Maxim, Seibert, Rachel, Parish, Chad, Norfolk, Mark, Terrani, Kurt, and Babu, Sudarsanam Suresh. Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing. United States: N. p., 2016.
Web. doi:10.1016/j.actamat.2016.06.048.
Sridharan, Niyanth, Gussev, Maxim, Seibert, Rachel, Parish, Chad, Norfolk, Mark, Terrani, Kurt, & Babu, Sudarsanam Suresh. Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing. United States. https://doi.org/10.1016/j.actamat.2016.06.048
Sridharan, Niyanth, Gussev, Maxim, Seibert, Rachel, Parish, Chad, Norfolk, Mark, Terrani, Kurt, and Babu, Sudarsanam Suresh. Thu .
"Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing". United States. https://doi.org/10.1016/j.actamat.2016.06.048. https://www.osti.gov/servlets/purl/1360032.
@article{osti_1360032,
title = {Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing},
author = {Sridharan, Niyanth and Gussev, Maxim and Seibert, Rachel and Parish, Chad and Norfolk, Mark and Terrani, Kurt and Babu, Sudarsanam Suresh},
abstractNote = {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.},
doi = {10.1016/j.actamat.2016.06.048},
journal = {Acta Materialia},
number = C,
volume = 117,
place = {United States},
year = {Thu Sep 01 00:00:00 EDT 2016},
month = {Thu Sep 01 00:00:00 EDT 2016}
}
Free Publicly Available Full Text
Publisher's Version of Record
Other availability
Search WorldCat to find libraries that may hold this journal
Cited by: 70 works
Citation information provided by
Web of Science
Web of Science
Save to My Library
You must Sign In or Create an Account in order to save documents to your library.
Works referenced in this record:
Characterization of interfacial microstructures in 3003 aluminum alloy blocks fabricated by ultrasonic additive manufacturing
journal, August 2010
- Dehoff, R. R.; Babu, S. S.
- Acta Materialia, Vol. 58, Issue 13
Effect of process parameters on bond formation during ultrasonic consolidation of aluminum alloy 3003
journal, January 2006
- Janaki Ram, G. D.; Yang, Y.; Stucker, B. E.
- Journal of Manufacturing Systems, Vol. 25, Issue 3
Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process
journal, December 2003
- Kong, C. Y.; Soar, R. C.; Dickens, P. M.
- Materials Science and Engineering: A, Vol. 363, Issue 1-2
Optimum process parameters for ultrasonic consolidation of 3003 aluminium
journal, February 2004
- Kong, C. Y.; Soar, R. C.; Dickens, P. M.
- Journal of Materials Processing Technology, Vol. 146, Issue 2
Statistical Characterization of Ultrasonic Additive Manufacturing Ti/Al Composites
journal, September 2010
- Hopkins, C. D.; Dapino, M. J.; Fernandez, S. A.
- Journal of Engineering Materials and Technology, Vol. 132, Issue 4
A Method for Bond Strength Evaluation for Laminated Structures with Application to Ultrasonic Consolidation
journal, November 2009
- Zhang, Chunbo (Sam); Deceuster, Andrew; Li, Leijun
- Journal of Materials Engineering and Performance, Vol. 18, Issue 8
Quantitative Evaluation of Bulk and Interface Microstructures in Al-3003 Alloy Builds Made by Very High Power Ultrasonic Additive Manufacturing
journal, September 2011
- Fujii, Hiromichi T.; Sriraman, M. R.; Babu, S. S.
- Metallurgical and Materials Transactions A, Vol. 42, Issue 13
Fundamentals of Solid-Phase Welding
journal, January 1962
- Milker, D. R.; Rowe, G. W.
- International Materials Reviews, Vol. 7, Issue 1
Behaviour of oxides during friction stir welding of aluminium alloy and their effect on its mechanical properties
journal, January 2002
- Okamura, H.; Aota, K.; Sakamoto, M.
- Welding International, Vol. 16, Issue 4
FIB-assisted TEM study of an oxide array in the root of a friction stir welded aluminium alloy
journal, February 2004
- Sato, Yutaka S.; Yamashita, Fumie; Sugiura, Yusuke
- Scripta Materialia, Vol. 50, Issue 3
Mechanism of weld formation during very-high-power ultrasonic additive manufacturing of Al alloy 6061
journal, August 2014
- Shimizu, S.; Fujii, H. T.; Sato, Y. S.
- Acta Materialia, Vol. 74
Microstructure evolution of 6061 O Al alloy during ultrasonic consolidation: An insight from electron backscatter diffraction
journal, April 2010
- Mariani, E.; Ghassemieh, E.
- Acta Materialia, Vol. 58, Issue 7
Shear Localization in Dynamic Deformation: Microstructural Evolution
journal, February 2008
- Xu, Yongbo; Zhang, Jinghua; Bai, Yilong
- Metallurgical and Materials Transactions A, Vol. 39, Issue 4
Plastic deformation and creep damage evaluations of type 316 austenitic stainless steels by EBSD
journal, October 2010
- Yoda, Rika; Yokomaku, Toshinori; Tsuji, Nobuhiro
- Materials Characterization, Vol. 61, Issue 10
Two-dimensional digital image correlation for in-plane displacement and strain measurement: a review
journal, April 2009
- Pan, Bing; Qian, Kemao; Xie, Huimin
- Measurement Science and Technology, Vol. 20, Issue 6
Accumulative roll bonding of aluminum alloys 2219/5086 laminates: Microstructural evolution and tensile properties
journal, April 2012
- Roy, Shibayan; Nataraj, B. R.; Suwas, Satyam
- Materials & Design (1980-2015), Vol. 36
Optimized welding parameters for Al 6061 ultrasonic additive manufactured structures
journal, July 2014
- Wolcott, Paul J.; Hehr, Adam; Dapino, Marcelo J.
- Journal of Materials Research, Vol. 29, Issue 17
The Effect of Anvil Geometry and Welding Energy on Microstructures in Ultrasonic Spot Welds of AA6111-T4
journal, April 2007
- Jahn, R.; Cooper, R.; Wilkosz, D.
- Metallurgical and Materials Transactions A, Vol. 38, Issue 3
Progress in cold roll bonding of metals
journal, April 2008
- Li, Long; Nagai, Kotobu; Yin, Fuxing
- Science and Technology of Advanced Materials, Vol. 9, Issue 2
Shear localization and recrystallization in dynamic deformation of 8090 Al–Li alloy
journal, February 2001
- Xu, Y. B.; Zhong, W. L.; Chen, Y. J.
- Materials Science and Engineering: A, Vol. 299, Issue 1-2
Microstructures and mechanical properties of 6061 aluminum alloy processed by accumulative roll-bonding
journal, February 2002
- Lee, S. H.; Saito, Y.; Sakai, T.
- Materials Science and Engineering: A, Vol. 325, Issue 1-2
Friction Skew-stir welding of lap joints in 5083–0 aluminium
journal, June 2005
- Cantin, G. M. D.; David, S. A.; Thomas, W. M.
- Science and Technology of Welding and Joining, Vol. 10, Issue 3
Plastic flow and work hardening of Al alloy matrices during ultrasonic consolidation fibre embedding process
journal, December 2008
- Li, Dezhi; Soar, Rupert C.
- Materials Science and Engineering: A, Vol. 498, Issue 1-2
A Review of Strain Analysis Using Electron Backscatter Diffraction
journal, March 2011
- Wright, Stuart I.; Nowell, Matthew M.; Field, David P.
- Microscopy and Microanalysis, Vol. 17, Issue 3
An experimental study of the formation process of adiabatic shear bands in a structural steel
journal, January 1988
- Marchand, A.; Duffy, J.
- Journal of the Mechanics and Physics of Solids, Vol. 36, Issue 3
Effect of Strain Rate Upon Plastic Flow of Steel
journal, January 1944
- Zener, C.; Hollomon, J. H.
- Journal of Applied Physics, Vol. 15, Issue 1
3-D growth of a short fatigue crack within a polycrystalline microstructure studied using combined diffraction and phase-contrast X-ray tomography
journal, January 2011
- Herbig, Michael; King, Andrew; Reischig, Péter
- Acta Materialia, Vol. 59, Issue 2
Effect of heat treatment on adiabatic shear bands in a high-strength low alloy steel
journal, March 2006
- Odeshi, A. G.; Bassim, M. N.; Al-Ameeri, S.
- Materials Science and Engineering: A, Vol. 419, Issue 1-2
Works referencing / citing this record:
Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture
journal, December 2016
- Hehr, Adam; Wenning, Justin; Terrani, Kurt
- JOM, Vol. 69, Issue 3
A Survey of Modeling of Lattice Structures Fabricated by Additive Manufacturing
journal, August 2017
- Dong, Guoying; Tang, Yunlong; Zhao, Yaoyao Fiona
- Journal of Mechanical Design, Vol. 139, Issue 10
Perspective of additive manufacturing for metamaterials development
journal, August 2019
- Wu, Xin; Su, Yutai; Shi, Jing
- Smart Materials and Structures, Vol. 28, Issue 9
Mechanical properties and microstructure evolution of dissimilar Mg and Al alloys welded using ultrasonic spot welding
journal, May 2019
- Li, Mingfeng; Zhu, Zhengqiang; Xiao, Qiankun
- Materials Research Express, Vol. 6, Issue 8
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
journal, September 2019
- Sridharan, Niyanth; Chen, Yimeng; Nandwana, Peeyush
- Journal of Materials Science, Vol. 55, Issue 4
Additive Manufacturing of Metallic Materials: A Review
journal, May 2017
- Zhang, Yi; Wu, Linmin; Guo, Xingye
- Journal of Materials Engineering and Performance, Vol. 27, Issue 1
Metal Alloys for Fusion-Based Additive Manufacturing
journal, February 2018
- Zhang, Duyao; Sun, Shoujin; Qiu, Dong
- Advanced Engineering Materials, Vol. 20, Issue 5
Ultrasonic additive manufacturing of 4130 steel using Ni interlayers
journal, May 2019
- Kuo, Chih-Hsiang; Sridharan, Niyanth; Han, Tianyang
- Science and Technology of Welding and Joining, Vol. 24, Issue 5