Multi-Material Ultrasonic Consolidation

Ultrasonic consolidation (UC) is a recently developed direct metal solid freeform fabrication process. While the process has been well-demonstrated for part fabrication in Al alloy 3003 H18, including with intricate cooling channels, some of the potential strengths of the process have not been fully exploited. One of them is its flexibility with build materials and the other is its suitability for fabrication of multi-material and functionally graded material parts with enhanced functional or mechanical properties. Capitalizing on these capabilities is critical for broadening the application range and commercial utilization of the process. In the current work, UC was used to investigate ultrasonic bonding of a broad range of engineering materials, which included stainless steels, Ni-base alloys, brass, Al alloys, and Al alloy composites. UC multimaterial part fabrication was examined using Al alloy 3003 as the bulk part material and the above mentioned materials as performance enhancement materials. Studies were focused on microstructural aspects to evaluate interface characteristics between dissimilar material layers. The results showed that most of these materials can be successfully bonded to Al alloy 3003 and vice versa using the ultrasonic consolidation process. Bond formation and interface characteristics between various material combinations are discussed based on oxide layer characteristics, material properties, and others.Mechanical Engineerin

Total variation regularization of multi-material topology optimization

This work is concerned with the determination of the diffusion coefficient from distributed data of the state. This problem is related to homogenization theory on the one hand and to regularization theory on the other hand. An approach is proposed which involves total variation regularization combined with a suitably chosen cost functional that promotes the diffusion coefficient assuming prespecified values at each point of the domain. The main difficulty lies in the delicate functional-analytic structure of the resulting nondifferentiable optimization problem with pointwise constraints for functions of bounded variation, which makes the derivation of useful pointwise optimality conditions challenging. To cope with this difficulty, a novel reparametrization technique is introduced. Numerical examples using a regularized semismooth Newton method illustrate the structure of the obtained diffusion coefficient.

A continues multi-material toolpath planning for tissue scaffolds with hollowed features

This paper presents a new multi-material based toolpath planning methodology for porous tissue scaffolds with multiple hollowed features. Ruled surface with hollowed features generated in our earlier work is used to develop toolpath planning. Ruling lines are reoriented to enable continuous and uniform size multi-material printing through them in two steps. Firstly, all ruling lines are matched and connected to eliminate start and stops during printing. Then, regions with high number of ruling lines are relaxed using a relaxation technique to eliminate over deposition. A novel layer-by-layer deposition process is progressed in two consecutive layers: The first layer with hollow shape based zigzag pattern and the next layer with spiral pattern deposition. Heterogeneous material properties are mapped based on the parametric distances from the hollow features

A conservative sharp-interface method for compressible multi-material flows

In this paper we develop a conservative sharp-interface method dedicated to simulating multiple compressible fluids. Numerical treatments for a cut cell shared by more than two materials are proposed. First, we simplify the interface interaction inside such a cell with a reduced model to avoid explicit interface reconstruction and complex flux calculation. Second, conservation is strictly preserved by an efficient conservation correction procedure for the cut cell. To improve the robustness, a multi-material scale separation model is developed to consistently remove non-resolved interface scales. In addition, the multi-resolution method and local time-stepping scheme are incorporated into the proposed multi-material method to speed up the high-resolution simulations. Various numerical test cases, including the multi-material shock tube problem, inertial confinement fusion implosion, triple-point shock interaction and shock interaction with multi-material bubbles, show that the method is suitable for a wide range of complex compressible multi-material flows

An adaptive Cartesian embedded boundary approach for fluid simulations of two- and three-dimensional low temperature plasma filaments in complex geometries

We review a scalable two- and three-dimensional computer code for low-temperature plasma simulations in multi-material complex geometries. Our approach is based on embedded boundary (EB) finite volume discretizations of the minimal fluid-plasma model on adaptive Cartesian grids, extended to also account for charging of insulating surfaces. We discuss the spatial and temporal discretization methods, and show that the resulting overall method is second order convergent, monotone, and conservative (for smooth solutions). Weak scalability with parallel efficiencies over 70\% are demonstrated up to 8192 cores and more than one billion cells. We then demonstrate the use of adaptive mesh refinement in multiple two- and three-dimensional simulation examples at modest cores counts. The examples include two-dimensional simulations of surface streamers along insulators with surface roughness; fully three-dimensional simulations of filaments in experimentally realizable pin-plane geometries, and three-dimensional simulations of positive plasma discharges in multi-material complex geometries. The largest computational example uses up to $800$ million mesh cells with billions of unknowns on $4096$ computing cores. Our use of computer-aided design (CAD) and constructive solid geometry (CSG) combined with capabilities for parallel computing offers possibilities for performing three-dimensional transient plasma-fluid simulations, also in multi-material complex geometries at moderate pressures and comparatively large scale.Comment: 40 pages, 21 figure

Virtual Simulation for Multi-material LM Process

In an ONR funded MURI program, to improve quality of multi-material parts, we've been developing an advanced computer simulation for the multi-material layered manufacturing (LM) process. The CAD models and their .stLfiles are created using. the commercially available software such as I-DEAS and ProE. Using this information, one tool path file per material is generated. Our file preparation algorithm, systematically, layer by layer, integrates all tool path files into one multi-material tool path file. The results of the multi-material tool path are graphically visualized using the simulation algorithm (written in c++ & SGI OpenGL). From a virtual simulation, we can check the LM process, and make the best selection of tool path parameters afterwards. After several trials from design to simulation, if the simulation result is acceptable, the real manufacturing can be started. And the part's quality should be better than a part manufactured without running simulation in advance. This paper will represent .•. new studies on using real toadshapes to get more realistic simulation results. Many parts have been successfully simulated using our method.Mechanical Engineerin