An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B23K 20/227 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
B23K 20/233 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
C22C 45/10 - Amorphous alloys with molybdenum, tungsten, niobium, tantalum, titanium, or zirconium as the major constituent
C23C 4/00 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 4/067 - Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
C23C 4/08 - Metallic material containing only metal elements
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 4/137 - Spraying in vacuum or in an inert atmosphere
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B23K 26/0622 - Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
B23K 26/00 - Working by laser beam, e.g. welding, cutting or boring
B23K 26/352 - Working by laser beam, e.g. welding, cutting or boring for surface treatment
B23K 20/227 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
B23K 20/233 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
C23C 4/067 - Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
C23C 4/00 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 4/08 - Metallic material containing only metal elements
C23C 4/137 - Spraying in vacuum or in an inert atmosphere
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.
B06B 3/00 - Processes or apparatus specially adapted for transmitting mechanical vibrations of infrasonic, sonic or ultrasonic frequency
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
F16C 23/08 - Ball or roller bearings self-adjusting
G10K 11/00 - Methods or devices for transmitting, conducting or directing sound in generalMethods or devices for protecting against, or for damping, noise or other acoustic waves in general
4.
HIGH-EFFICIENCY WELDING ASSEMBLY FOR USE IN ULTRASONIC ADDITIVE MANUFACTURING
An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
F16C 23/08 - Ball or roller bearings self-adjusting
5.
SYSTEMS AND DEVICES FOR QUALITY MONITORING OF ADDITIVE MANUFACTURING PROCESSES
A system for use in characterizing parts made by additive manufacturing processes, comprising a sensing device having an upper surface and a lower surface; at least one channel formed in the upper surface of the sensing device, wherein the at least one channel is formed to a predetermined depth in the upper surface of the sensing device, and wherein the at least one channel is formed in a predetermined pattern across the upper surface of the sensing device; and a sensor disposed within each channel formed in the upper surface of the sensing device, wherein each sensor is operative to gather information relevant to an additive manufacturing process occurring on or in close proximity to the sensing device.
A system for use in characterizing parts made by additive manufacturing processes, comprising a sensing device having an upper surface and a lower surface; at least one channel formed in the upper surface of the sensing device, wherein the at least one channel is formed to a predetermined depth in the upper surface of the sensing device, and wherein the at least one channel is formed in a predetermined pattern across the upper surface of the sensing device; and a sensor disposed within each channel formed in the upper surface of the sensing device, wherein each sensor is operative to gather information relevant to an additive manufacturing process occurring on or in close proximity to the sensing device.
An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B23K 20/233 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
B33Y 70/00 - Materials specially adapted for additive manufacturing
B23K 20/227 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
B23K 26/0622 - Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C23C 4/067 - Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 4/00 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 4/08 - Metallic material containing only metal elements
C23C 4/137 - Spraying in vacuum or in an inert atmosphere
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
A sacrificial material for use in ultrasonic additive manufacturing processes that includes at least one water-soluble solid; and at least one water-soluble binding agent, wherein the at least one water-soluble solid is partially dissolved or suspended in the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B29C 65/08 - Joining of preformed partsApparatus therefor by heating, with or without pressure using ultrasonic vibrations
C08L 29/04 - Polyvinyl alcoholPartially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
9.
SOLUBLE SACRIFICIAL MATERIALS FOR USE IN ULTRASONIC ADDITIVE MANUFACTURING
A sacrificial material for use in ultrasonic additive manufacturing processes that includes at least one water-soluble solid; and at least one water-soluble binding agent, wherein the at least one water-soluble solid is partially dissolved or suspended in the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B29C 65/08 - Joining of preformed partsApparatus therefor by heating, with or without pressure using ultrasonic vibrations
C08L 29/04 - Polyvinyl alcoholPartially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
10.
WELD ASSEMBLY FOR ULTRASONIC ADDITIVE MANUFACTURING APPLICATIONS
A system for use in ultrasonic additive manufacturing processes, wherein the system includes a milling machine or the like and a weld assembly. The milling machine further includes a spindle adapted to receive a milling tool, wherein the spindle is capable of moving in the z-axis direction; and a table positioned beneath the spindle, wherein the table is capable of moving in the x-axis direction and the y-axis direction. The weld assembly is adapted to be mounted on the spindle of the milling machine and further includes an ultrasonic weld head; a tapered tool shank adapted to connect the weld assembly to the spindle; and a unique mating collar disposed between the ultrasonic weld head and the spindle, wherein the mating collar is operative transfer thrust loads associated with ultrasonic additive manufacturing processes from the ultrasonic weld head to the z-axis of the spindle without damaging the spindle or other components of the machine.
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B23K 20/10 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
B23K 35/02 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
patents
