Improving Linear Weld Density in Ultrasonically Consolidated Parts

Ultrasonic consolidation is a novel additive manufacturing process with immense potential for fabrication of complex shaped three-dimensional metallic objects from metal foils. The proportion of bonded area to unbonded area along the layer interface, termed linear weld density (LWD), is perhaps the most important quality attribute of ultrasonically consolidated parts. Part mechanical properties largely depend on LWD and a high level of LWD must be ensured in parts intended for load-bearing structural applications. It is therefore necessary to understand what factors influence LWD or defect formation and devise methods to enhance bond formation during ultrasonic consolidation. The current work examines these issues and proposes strategies to ensure near 100% LWD in ultrasonically consolidated aluminum alloy 3003 parts. The work elucidates the effects of various process parameters on LWD and a qualitative understanding of the effects of process parameters on bond formation during ultrasonic consolidation is presented. The beneficial effects of using elevated substrate temperatures and its implications on overall manufacturing flexibility are discussed. A preliminary understanding of defect morphologies and defect formation is presented, based on which a method (involving surface machining) for minimizing defect incidence during ultrasonic consolidation is proposed and demonstrated. Finally, trade-offs between part quality and build time are discussed.Mechanical Engineerin

Modal analysis and nonlinear characterization of an airborne power ultrasonic transducer with rectangular plate radiator

Some industrial processes like particle agglomeration or food dehydration among others can be enhanced by the use of power ultrasonic technologies. These technologies are based on an airborne power ultrasonic transducer (APUT) constituted by a pre-stressed Langevin-type transducer, a mechanical amplifier and an extensive plate radiator. In order to produce the desired effects in industrial processing, the transducer has to vibrate in an extensional mode driving an extensive radiator in the desired flexural mode with high amplitude displacements. Due to the generation of these high amplitude displacements in the radiator surfaces, non-linear effects like frequency shifts, hysteresis or modal interactions, among others, may be produced in the transducer behavior. When any nonlinear effect appears, when applying power, the stability and efficiency of this ultrasonic technology decreases, and the transducer may be damaged depending on the excitation power level and the nature of the nonlinearity. In this paper, an APUT with flat rectangular radiator is presented, as the active part of an innovative system with stepped reflectors. The nonlinear behavior of the APUT has been characterized numerically and experimentally in case of the modal analysis and experimentally in the case of dynamic analysis. According to the results obtained after the experiments, no modal interactions are expected, nor do other nonlinear effects

Nitinol Cymbal Transducers for Power Ultrasonics Applications

The effects of shape memory alloy phenomena such as superelasticity and thermal phase change on the dynamic response of a cymbal transducer incorporating two Nitinol end-caps has not been studied into detail. The experimental results, using both vibration response and electrical impedance measurements, demonstrate that the use of Nitinol as the end-cap material for a cymbal transducer can impose significant effects on the vibration response. The understanding of the effect Nitinol has on the vibration response of a cymbal transducer provides future opportunities to design a power ultrasonic cymbal transducer that can operate with two different and selectable vibration behaviours, which is particularly appealing in a range of applications, including ultrasonic cutting devices that are required to penetrate more than one material

Shannon Entropy as Characterization Tool in Acoustics

We introduce Shannon's information entropy to characterize the avoided crossing appearing in the resonant Zener-like phenomenon in ultrasonic superlattices made of two different fluidlike meta- materials. We show that Shannon's entropy gives a correct physical insight of the localization effects taking place and manifest the informational exchange of the involved acoustic states in the narrow region of parameters where the avoided crossing occurs. Results for ultrasonic structures consisting of alternating layers of methyl-metacrylate and water cavities, in which the acoustic Zener effect were recently demonstrated, are also reported.Comment: 4 pages, 5 figures. Submitted to Phys. Rev. Let

Ultrasonic Production of Nano-Size Dispersions and Emulsions

Ultrasound is a well-established method for particle size reduction in dispersions and emulsions. Ultrasonic processors are used in the generation of nano-size material slurries, dispersions and emulsions because of the potential in the deagglomeration and the reduction of primaries. These are the mechanical effects of ultrasonic cavitation. Ultrasound can also be used to influence chemical reactions by the cavitation energy. This is sonochemistry. As the market for nano-size materials grows, the demand for ultrasonic processes at production level increases. At this stage, energy efficiency becomes important. Since the energy required per weight or volume of processed material links directly to the equipment size required, optimization of the process efficiency is essential to reduce investment and operational costs. Furthermore it is required to scale the lab and bench top configurations to this final level without any variations in the process achievements. Scale up by power alone will not do this.Comment: Submitted on behalf of TIMA Editions (http://irevues.inist.fr/tima-editions

Optimizing signal-to-error ratio in standing wave ultrasonic measurements

Standing wave ultrasonic techniques for the measurement of very small changes in acoustic attenuation and phase velocity are discussed. Enhanced sensitivity to these small changes was achieved by making the specimen part of a composite ultrasonic resonator. It was found that a point of maximum sensitivity on the response of such an ultrasonic resonator need not coincide with a point of maximum signal-to-error ratio. A model is presented and analyzed which takes into account error due to long term (low frequency) noise effects such as gain drifts and dc level shifts. This model yields a quantitative value for the signal-to-error ratio in which the signal is defined as the ideal change in the monitored response and the error as the difference between the experimentally measured change and the signal. The specific frequency dependent forms for the ultrasonic response and the sensitivity enhancement factor were used to predict the operating point on a mechanical resonance corresponding to maximum signal-to-error ratio

Development of limb volume measuring system

The mechanisms underlying the reductions in orthostatic tolerance associated with weightlessness are not well established. Contradictory results from measurements of leg volume changes suggest that altered venomotor tone and reduced blood flow may not be the only contributors to orthostatic intolerance. It is felt that a more accurate limb volume system which is insensitive to environmental factors will aid in better quantification of the hemodynamics of the leg. Of the varous limb volume techniques presently available, the ultrasonic limb volume system has proven to be the best choice. The system as described herein is free from environmental effects, safe, simple to operate and causes negligible radio frequency interference problems. The segmental ultrasonic ultrasonic plethysmograph is expected to provide a better measurement of limb volume change since it is based on cross-sectional area measurements

The effect of internal pipe wall roughness on the accuracy of clamp-on ultrasonic flow meters

Clamp-on transit-time ultrasonic flowmeters (UFMs) suffer from poor accuracy compared with spool-piece UFMs due to uncertainties that result from the in-field installation process. One of the important sources of uncertainties is internal pipe wall roughness which affects the flow profile and also causes significant scattering of ultrasound. This paper purely focuses on the parametric study to quantify the uncertainties (related to internal pipe wall roughness) induced by scattering of ultrasound and it shows that these effects are large even without taking into account the associated flow disturbances. The flowmeter signals for a reference clamp-on flowmeter setup were simulated using 2-D finite element analysis including simplifying assumptions (to simulate the effect of flow) that were deemed appropriate. The validity of the simulations was indirectly verified by carrying out experiments with different separation distances between ultrasonic probes. The error predicted by the simulations and the experimentally observed errors were in good agreement. Then, this simulation method was applied on pipe walls with rough internal surfaces. For ultrasonic waves at 1 MHz, it was found that compared with smooth pipes, pipes with only a moderately rough internal surface (with 0.2-mm rms and 5-mm correlation length) can exhibit systematic errors of 2 in the flow velocity measurement. This demonstrates that pipe internal surface roughness is a very important factor that limits the accuracy of clamp on UFMs