Manufacturing Process Optimization of Ultrasonic Bonding of Metallic Composites

Award Information
Agency: Department of Defense
Branch: Army
Contract: W15QKN-12-P-0153
Agency Tracking Number: A12A-004-0106
Amount: $99,999.00
Phase: Phase I
Program: STTR
Awards Year: 2012
Solicitation Year: 2012
Solicitation Topic Code: A12a-T004
Solicitation Number: 2012.A
Small Business Information
407 Front Street, Schenectady, NY, -
DUNS: 799645916
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 David Hauber
 Technical Director
 (518) 377-6471
 dhauber@automateddynamics.com
Business Contact
 Robert Langone
Title: President
Phone: (518) 377-6471
Email: rlangone@automateddynamics.com
Research Institution
 Edison Welding Institute
 Karl Graff
 1250 Arthur E Adams Drive
Columbus, OH, 43221-3585
 (614) 688-5000
 Domestic nonprofit research organization
Abstract
This project will build on a substantial body of empirical research to develop and validate multiscale models of ultrasonic bonding during tape placement of metal matrix composite (MMC) structures. Experiments to-date have been guided by knowledge of the ultrasonic bonding of metals heuristically applied to the more complex problem of bonding MMCs. While all scales are of interest in a complete understanding of ultrasonic additive manufacturing (UAM) of MMCs, we will focus on the largest and most relevant scales initially. By using multiscale models that simulate how materials respond to processing conditions we can reduce the number of large-scale experiments while shortening the development cycle. Current issues in UAM of MMCs include first ply bond, surface morphology, thermal/ultrasonic process window, thermally induced stress, work hardening, void dynamics, reinforcement damage, and structural resonances. UAM is currently being used for rapid prototypes including tooling, embedded sensors, and other applications. UAM with MMCs is ideal for high performance applications such as reinforced gun & mortar tubes for sustained fire as well as other military, industrial, downhole, and aerospace structures where service temperatures exceed the capabilities of polymer matrix composites.

* Information listed above is at the time of submission. *

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