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Proceedings Paper

Aluminum-matrix composites with embedded Ni-Ti wires by ultrasonic consolidation
Author(s): Ryan Hahnlen; Marcelo J. Dapino; Matt Short; Karl Graff
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Paper Abstract

[Smart Vehicle Workshop] This paper presents the development of active aluminum-matrix composites manufactured by Ultrasonic Additive Manufacturing (UAM), an emerging rapid prototyping process based on ultrasonic metal welding. Composites created through UAM experience process temperatures as low as 20°C, in contrast to current metal-matrix fabrication processes which require fusion of materials and hence reach temperatures of 500°C and above. UAM thus creates unprecedented opportunities to develop adaptive structures with seamlessly embedded smart materials and electronic components without degrading the properties that make embedding these materials and components attractive. This research focuses on three aspects of developing UAM Ni-Ti/Al composites which have not been accomplished before: (i) Characterization of the mechanical properties of the composite matrix; (ii) Investigation of Ni-Ti/Al composites as tunable stiffness materials and as strain sensors based on the shape memory effect; and (iii) Development of constitutive models for UAM Ni-Ti/Al composites. The mechanical characterization shows an increase in tensile strength of aluminum UAM builds over the parent material (Al 3003-H18), likely due to grain refinement caused by the UAM process. We demonstrate the ability to embed Ni-Ti wires up to 203 μm in diameter in an aluminum matrix, compared with only 100 μm in previous studies. The resulting Ni-Ti/Al UAM composites have cross sectional area ratios of up to 13.4% Ni-Ti. These composites exhibit a change in stiffness of 6% and a resistivity change of -3% when the Ni- Ti wires undergo martensite to austenite transformation. The Ni-Ti area ratios and associated strength of the shape memory effect are expected to increase as the UAM process becomes better understood and is perfected. The Brinson constitutive model for shape memory transformations is used to describe the stiffness and the strain sensing of Ni-Ti/Al composites in response to temperature changes.

Paper Details

Date Published: 31 March 2009
PDF: 12 pages
Proc. SPIE 7290, Industrial and Commercial Applications of Smart Structures Technologies 2009, 729009 (31 March 2009); doi: 10.1117/12.817036
Show Author Affiliations
Ryan Hahnlen, The Ohio State Univ. (United States)
Marcelo J. Dapino, The Ohio State Univ. (United States)
Matt Short, Edison Welding Institute (United States)
Karl Graff, Edison Welding Institute (United States)


Published in SPIE Proceedings Vol. 7290:
Industrial and Commercial Applications of Smart Structures Technologies 2009
Benjamin K. Henderson; M. Brett McMickell, Editor(s)

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