Research Information System
Thesis Type: Postgraduate
Institution Of The Thesis: Gazi University, Fen Bilimleri Enstitüsü, Turkey
Approval Date: 2023
Thesis Language: Turkish
Student: Muhammet KURT
Supervisor: Oğuzhan Yılmaz
Abstract:
Compared with conventional manufacturing technologies, metal additive manufacturing
technologies which are one of the most popular manufacturing methods of recent times, has a very bright future with its possible application fields, ease of manufacturing of various parts, independence from traditional design constraints, compatibility for design optimizations and rapidly developing technological infrastructure. Due to this potential of metal additive manufacturing technologies, different scientific studies are carried out in various subclasses that can be included in this technology. Ultrasonic metal additive manufacturing, which is one of these subclasses is an additive manufacturing method based on the consolidation of thin metal foils of the same or different types in a layered manner by ultrasonic welding which is a solid state welding. In this study, in order to examine the foundations of ultrasonic additive manufacturing, an ultrasonic additive consolidation device was designed and manufactured. It was aimed to weld thin aluminum foils in a layered manner. In order to examine the relationship between static loading, amplitude and welding speed, which are the basic ultrasonic bonding parameters, and to understand the effect of these parameters on the ultrasonic bonding quality, the amplitude between 45-55 µm, static loading between 30-50 kg and welding speed between 4-10 rpm are specified. Consolidation experiments were carried out with 15 different parameter sets based on the ultrasonic additive consolidation of four aluminum foils. 11 of these experiments were successful and 4 were unsuccessful. Successful experiments were subjected to the peel test. As a result of these tests, with the experimental set consisting of 55 µm amplitude, 40 kg static loading and 10rpm welding speed, the highest peel test value of 185 N was obtained. After ultrasonic bonding, three specimens were prepared and the ultrasonic bonding interfaces of these specimens were examined under a scanning electron microscope and surface defects at the bonding interfaces were detected and the linear weld density along the ultrasonic bonding interfaces was calculated as 90%.
Key Words : Ultrasonic metal additive manufacturing, ultrasonic welding, ultrasonic bonding parameters.