Ultrasonic Consolidation (UC) is a solid state additive manufacturing process which
fabricates three-dimensional objects by ultrasonically joining metal foils together, layer-bylayer,
to form a solid part. A wide range of materials can be used to fabricate parts by UC
and products with complex internal geometry can be generated by shaping the crosssection
throughout the build using Computer Numerically Controlled (CNC) milling. As a
result of its ability to embed various secondary materials and fibres in metal matrices, UC
has emerged as a potential method of fabricating multi-functional materials and structures. [Continues.]
A Doctoral Thesis. Submitted in partial fulfilment of the requirements for the award of Doctor of Philosophy of Loughborough University.