What is Ultrasonic Consolidation Technology ?

    Ultrasonic consolidation manufacturing technology is an advanced method of material and structure manufacturing. This technology is mainly based on the principle of metal ultrasonic vibration plastic processing. Metal foil is used as raw material, and the high frequency vibration of ultrasound is used to make the contact interface between layers pass through friction under the combined action of static pressure and elastic vibration energy. The effects of friction and temperature rise promote infinite approximation, bonding and diffusion of metal atoms between interfaces, and realize solid metallurgical bonding between layers. It is generally believed that friction, plastic flow and temperature are the necessary factors for ultrasonic consolidation, in which friction plays a dominant role. This is not only because friction is the main heat source in consolidation, but also because the foil produces temperature rise and plastic flow. At the same time, friction can also remove oxide film, which creates conditions for atomic diffusion between foil interfaces. 

    The ultrasonic vibration system mainly consists of ultrasonic power supply, transducer, horn and tool head. Firstly, the ultrasonic electric signal with a frequency of not less than 20Khz is emitted by the ultrasonic power supply. The electrical signal is converted into the longitudinal mechanical vibration energy of the frequency phase by piezoelectric ceramics in the transducer, and the mechanical vibration amplitude is transformed by the horn. Enlarged to a certain extent, the tool head is output to the tool head, which realizes metal consolidation by contacting with the parts to be processed. The ultrasonic vibration system consisting of transducer, horn and tool head is supported by bearings, and the static pressure applied during consolidation is provided by the support structure. Ultrasonic consolidation belongs to continuous welding process. Therefore, it is necessary to drive the tool head to rotate continuously by adjusting the speed of motor. Through the coordinated matching of plane motion and rotation speed, the effective control of welding speed in the process of ultrasonic consolidation can be realized, and the phenomenon of tool head slipping on the foil surface can be avoided.

    Ultrasonic consolidation technology is developed on the basis of ultrasonic welding technology. It is an advanced method of material and structure manufacturing. This technology is mainly based on the principle of metal ultrasonic vibration plastic processing. It takes metal foil as raw material and makes use of the high frequency vibration of ultrasobic to make the contact interface between layers under static pressure and elasticity. Under the combined action of sexual vibration energy, the infinite approximation, bonding and diffusion of metal atoms between interfaces are promoted by friction and temperature rise, and the solid metallurgical bonding between layers is realized. This technology breaks through the traditional ultrasonic. The welding area is limited by the point and line, which realizes the consolidation between the metal surface and the surface.

    At the same time, the technology is highly designed. On the one hand, it combines the computer numerical control milling technology to realize the manufacturing and processing of three-dimensional metal parts. On the other hand, through matching different materials, it can produce a high-performance structure which can not be achieved by a single material. After more than 10 years of development, the theoretical system of ultrasonic consolidation manufacturing technology has been gradually improved, and the technology is relatively mature. As a new method of preparing high-performance composite materials, it is used to fabricate layered metal composite structures, functionally gradient material structures, fiber reinforced metal matrix composite structures and smart metal composite structures. There is great potential in these areas.