Ultrasonic Additive Manufacturing (UAM) is a 3D metal printing technology which does not utilize melting for part formation. Instead, ultrasonic scrubbing energy is used to join the metals together near room temperature without a controlled atmosphere. These attributes allow creation of large metal parts to be produced with aluminum alloys, dissimilar metals, and internal passageways for heat transfer devices. Recently, Fabrisonic has working with NASA and Virginia Tech on embedding fiber optic strain and temperature sensors in 3D printed metal for health monitoring applications in aerospace and nuclear applications. Since the process happens near room temperature, fiber optics and other electronic sensors can be embedded without damage. By embedding the sensor at critical locations, engineers are able to monitor health and predict structure life. Further this information can be fed backwards to the design and analysis team to increase the fidelity of analytical models. In aerospace, true strain-time histories allow engineers to more accurately set inspection intervals. In the nuclear industry, new sapphire fiber optic cables are resistant to radiation decay and can provide crucial in-pile health monitoring.
- Describe how solid state 3D printing occurs and the physics driving weld quality.
- Describe the constraints of solid state welding.
- Design parts with embedded sensors and demonstrate knowledge of prior real-world applications.