Ultrasonic Consolidation (UC) is a layer-by-layer metal-based additive
manufacturing process. Bonding between two layers is accomplished by energy
transmission in form of ultrasonic oscillations inducing localised plastic
deformation. The benefit of localised plastic deformation and bonding below
melting temperatures has been effectively used for fibre integration. Thus, UC
presents a feasible alternative to other metal-manufacturing processes as well
as an attractive method for novel engineering materials production such as
smart structures.Yet, high volume fibre embedding has been shown to result in
delamination of foils and greater porosity at the bonding interfaces due to
insufficient plastic flow around the fibres. Furthermore, post-functionality of
delicate fibre types was limited.
In this study a novel hybrid approach aiming to reduce the necessary plastic
flow around fibres and high fibre volume embedding is presented. [Continues.]
A Doctoral Thesis. Submitted in partial fulfilment of the requirements for the award of Doctor of Philosophy of Loughborough University.
EPSRC. Loughborough University, Innovative Manufacturing and Construction Research Centre (IMCRC).