Very High Power Ultrasonic Additive Manufacturing (VHP UAM) for Advanced Materials

Abstract

To extend current ultrasonic additive manufacturing (UAM) to advanced materials, higher speeds and larger parts, it was essential to greatly increase the process ultrasonic power. EWI, with Solidica™, several industry, agency and academic partners, and support of Ohio’s Wright Program, have developed a “Very High Power Ultrasonic Additive Manufacturing System” that greatly extends current technology. A key part was the design of a 9.0 kW “push-pull” ultrasonic system able to produce sound welds in materials such as Ti 6-4, 316SS, 1100 Cu and Al7075. The VHP system can fabricate parts of up to 1.5m x 1.5m x 0.6m, with process and software developments that enable forming contoured surfaces.