Research has been completed in order to rapidly manufacture spacecraft thermal control technologies embedded in spacecraft structural panels using ultrasonic consolidation. This rapid manufacturing process enables custom thermal control designs in the time frame necessary for responsive space. Successfully embedded components include temperature sensors, heaters, wire harnessing, pre-manufactured heat pipes, and custom integral heat pipes. High conductivity inserts and custom integral pulsating heat pipes were unsuccessfully attempted. This research shows the viability of rapid manufacturing of spacecraft structures with embedded thermal control using ultrasonic consolidation.

A fundamental investigation of the use of ultrasonic consolidation (UC) to produce deck panels for small satellites was undertaken. Several fabrication methods for producing structural panels and decking were analyzed. Because of its ability to create aluminum objects in an additive fashion, and at near-room temperatures, UC was found to be a powerful solution for creating highly integrated and modular satellite panels. It also allowed a lightweight and stiff deck to be fabricated without the use of adhesives. A series of experiments were performed to understand the issues associated with creating a sandwich-type structure using UC. The experiments used a peel test apparatus to evaluate the bond strength for various geometric configurations and materials. Aluminum 3003 was chosen as the sole material constituting the deck panel. The honeycomb lattice was found to offer the best core configuration due to its ability to resist vibration from the sonotrode and provide adequate support for pressure induced by the sonotrode. Support materials for enhancing the bonding of the facings to the core were investigated but did not lead to implementation. A CAD model was created to integrate the honeycomb core, facings, and modular bolt pattern into the ultrasonically consolidated structure. The model was used to develop a build procedure for fabricating the deck on the UC machine. A finite element analysis was performed that used an equivalent properties method to represent the deck. The stiffness of a prototype deck was evaluated in a three-point bending test and the results were found to correlate with the finite element model. A sine sweep vibration test was then performed on the prototype deck panel to measure its natural frequencies. Finally, a case study was performed on a deck built for the TOROID spacecraft. A final deck panel was designed using the results from the prototype. The deck included the USUSat bolt pattern, vented honeycomb, and a reinforced rim. The cost and benefits of the final deck panel versus traditional fabrication methods were outlined.

A research project was undertaken to integrate Ultrasonic Consolitation (UC) and Direct-Write (DW) technologies into a single apparatus to fabricate embedded electrical systems within an ultrasonically consolidated metallic enclosure. Process and design guidelines were developed after performing fundamental research on the operational capabilities of the implemented system. In order to develop such guidelines, numerous tests were performed on both UC and DW. The results from those tests, as well as the design and process guidelines for the fabrication of an embedded touch switch, can be used as a base for future research and experimentation on the UC-DW apparatus. The successful fabrication of an embedded touch switch proves the validity of the described design and process parameters and demonstrates the usefulness of this integration.

A dislocation density-based constitutive model has been developed and implemented into a crystal plasticity quasi-static finite element framework. This approach captures the statistical evolution of dislocation structures and grain fragmentation at the bonding interface when sufficient boundary conditions pertaining to the Ultrasonic Consolidation (UC) process are prescribed. The hardening is incorporated using statistically stored and geometrically necessary dislocation densities (SSDs and GNDs), which are dislocation analogs of isotropic and kinematic hardening, respectively. Since the macroscopic global boundary conditions during UC involves cyclic sinosuidal simple shear loading along with constant normal pressure, the cross slip mechanism has been included in the evolution equation for SSDs. The inclusion of cross slip promotes slip irreversibility, dislocation storage, and hence, cyclic hardening during the UC. The GND considers strain-gradient and thus renders the model size-dependent. The model is calibrated using experimental data from published refereed literature for simple shear deformation of single crystalline pure aluminum alloy and uniaxial tension of polycrystalline Aluminum 3003-H18 alloy. The model also incorporates various local and global effects such as (1) friction, (2) thermal softening, (3) acoustic softening, (4) surface texture of the sonotrode and initial mating surfaces, and (6) presence of oxide-scale at the mating surfaces, which further contribute significantly specifically to the grain substructure evolution at the interface and to the anisotropic bulk deformation away from the interface during UC in general. The model results have been predicted for Al-3003 alloy undergoing UC. A good agreement between the experimental and simulated results has been observed for the evolution of linear weld density and anisotropic global strengths macroscopically. Similarly, microscopic observations such as embrittlement due to grain substructure evolution at the UC interface have been also demonstrated by the simulation. In conclusion, the model was able to predict the effects of macroscopic global boundary conditions on bond quality. It has been found that the normal pressure enhances good bonding characteristics at the interface, though beyond a certain magnitude enhances dynamic failure. Similarly, lower oscillation amplitudes result in a lower rate of gap closure, whereas higher oscillation amplitude results in an enhanced rate of gap relaxation at the interface. Henceforth, good bonding characteristics between the constituent foils are found at an optimum oscillation amplitude. A similar analogy is also true for weld speed where the longitudinal locations behind the sonotrode rip open when higher weld speeds are implemented in the UC machine, leading to lower linear weld density and poor bonding characteristics.

This research is a systematic study exploring a new fabrication methodology for long-fiber-reinforced metal matrix composites (MMCs) using a novel additive manufacturing technology. The research is devoted to the manufacture of long-fiber-reinforced MMC structures using the Ultrasonic Consolidation (UC) process. The main objectives of this research are to investigate the bond formation mechanisms and fiber embedment mechanisms during UC, and further to study the effects of processing parameters on bond formation and fiber embedment, and the resultant macroscopic mechanical properties of UC-made MMC structures. From a fundamental research point of view, bond formation mechanisms and fiber embedment mechanisms have been clarified by the current research based on various experimental observations. It has been found that atomic bonding across nascent metal is the dominant bond formation mechanism during the UC process, whereas the embedded fiber are mechanically entrapped within matrix materials due to significant plastic deformation of the matrix material during embedment. From a manufacturing process point of view, the effects of processing parameters on bond formation and fiber embedment during the UC process have been studied and optimum levels of parameters have been identified for manufacture of MMC structures. An energy-based model has been developed as a first step toward analytically understanding the effects of processing parameters on the quality of ultrasonically consolidated structures. From a material applications point of view, the mechanical properties of ultrasonically consolidated structures with and without the presence of fibers have been characterized. The effects on mechanical properties of UC-made structures due to the presence of embedded fibers have been discussed.

Support materials play a vital role across the entire field of additive manufacturing (AM) technologies. They are essential to provide the ability to create complex structures and features using AM. Successful implementation of support materials in ultrasonic consolidation (UC) will provide a vast opportunity for improvement of geometric complexity. Experimentation was performed to evaluate suitable support materials and their effectiveness within UC. Additionally a fused deposition modeling (FDM) system was integrated into the UC build environment to create an automated support deposition system. Finally several unique structures were built using support materials to demonstrate the improved geometric capability and to develop design rules for use in UC.

Ultrasonic Consolidation of stainless steel structures is being investigated for potential applications. This study investigates the suitability of Stainless Steel 316L annealed (SS316L annealed) as a building material for Ultrasonic Consolidation (UC), including research on Linear Welding Density (LWD) estimation on micrographs of samples. Experiment results are presented that include the effect of UC process parameters on SS316L annealed UC, optimum levels of these parameters, and bond quality of ultrasonically consolidated SS316L annealed structures in terms of LWD. In support to these efforts, a Measurement System Analysis for LWD assessment has been performed, and a new instrument for LWD measurement was developed. This work will determine local maximum LWD UC process parameters for SS316L annealed structures based upon systematic evaluation of sample micrographs.

This research explores the use of two additive manufacturing processes for the fabrication of multi-material structures. Ultrasonic consolidation (UC) and laser- engineered net shaping (LENS) processes were used for parallel systematic investigations of the process parameters and methodologies for the development of multi-material structures. The UC process uses ultrasonic energy at low temperature to bond metallic foils. A wide range of metallic materials including nickel; titanium; copper; molybdenum; tantalum; MetPreg®; silver; stainless steel; and aluminum alloys 1100, 3003, and 6061 were bonded in different combinations. Material domains are inherently discrete in ultrasonically consolidated structures. The mechanical properties of some of the bonded structures were characterized to lay the groundwork for their real-life applications. LENS uses a laser beam to deposit metallic powder materials for the fabrication of fully dense structures. Mechanical testing was used to characterize the flexural and tensile properties of dual-material structures made of Ti6Al4V/10wt%TiC composite and Ti6Al4V materials. Experimental results show that the strength of transition joints in multi-material structures significantly depends on the joint design. Dual-material minimum weight structures, representing geometrically and materially complex structures, were fabricated using the results of the process parameters and fabrication methodologies developed in this work. The structures performed well under loading test conditions. It shows that function-specific multi-material structures ultrasonically consolidated and LENS fabricated can perform well in real-life applications.

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