Systems and methods for joining and repair using ultrasonic additive manufacturing with a contoured sonotrode
AssigneeOhio State Innovation Foundation
InventorsMarcelo Dapino, Leon Headings, Mark Gingerich
Life of this patent
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Abstract
An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.
Claims20
An ultrasonic additive manufacturing system comprising:
- a base structure;
- a sonotrode configured to rotate about an axis of rotation, wherein the sonotrode comprises a welding surface extending along a circumference of the sonotrode, wherein the welding surface has a contoured profile, and wherein at least one of the sonotrode and the base structure is configured to translate relative to the other of the sonotrode and the base structure;
- and
- one or more transducers configured to vibrate the sonotrode.
A method for joining a first metal structure and a second metal structure using ultrasonic additive manufacturing, the method comprising:
- positioning the first metal structure and the second metal structure adjacent one another;
- creating a first channel along a first side of an interface between the first metal structure and the second metal structure, wherein the first channel has a first contoured profile;
- and
- welding, via a sonotrode, one or more first metal foils at least partially within the first channel, wherein the sonotrode comprises a welding surface extending along a circumference of the sonotrode, and wherein the welding surface has a second contoured profile.
A method for repairing a defect in a metal structure using ultrasonic additive manufacturing, the method comprising:
- creating a channel in the metal structure such that the defect is removed from the metal structure, wherein the channel has a first contoured profile;
- and
- welding, via a sonotrode, one or more metal foils at least partially within the channel, wherein the sonotrode comprises a welding surface extending along a circumference of the sonotrode, and wherein the welding surface has a second contoured profile.
Dependencies are inferred from the claim text.