Optimum process parameters for ultrasonic consolidation of 3003 aluminium

In this paper, the ultrasonic consolidation (UC) process is presented for the direct fabrication of monolithic aluminium tooling and components. UC is a solid-state process that involves the use of high frequency, low amplitude, mechanical vibrations to bond metal foils in a layer-by-layer method. The work, described in this paper, centres on the characterisation of aluminium 3003 foils that will be used in a freeform fabrication process with industrial applications. This paper describes the first phase of ongoing research which involves the identification of the optimum process parameters when producing multi-layered specimens using UC test apparatus. A general process window for aluminium 3003, welded under UC conditions, is identified, based on the combination of data generated from modified peel test and microstructural analysis experiments.