| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Designing Complex Microstructures through Additive Manufacturing
|
| Presentation Title |
Ultrasonic Vibration-Assisted Direct Energy Deposition 3D Printing of High-Strength Aluminum Alloys |
| Author(s) |
Lovejoy Mutswatiwa, Judith A Todd, Edward W. Reutzel, Brady Sawyer, Cory D. Jamieson, Christopher M. Kube |
| On-Site Speaker (Planned) |
Lovejoy Mutswatiwa |
| Abstract Scope |
Additive manufacturing (AM) offers advantages, including geometric flexibility and material grading capabilities over conventional fabrication techniques. However, the range of printable alloys is restricted due to solidification cracking and intolerable microstructures. Ultrasonic melt processing presents a promising solution to refine grains and reduce defects without changing the alloy composition. This presentation will highlight how varying amplitudes and intensities impact grain refinement and solidification in ultrasonic vibration-assisted direct energy deposition (DED) AM of Al7075 and Scalmalloy. We custom-designed an Al7075 rectangular substrate, equipped with a high-power ultrasonic transducer, for installation in the DMG MORI LASERTEC65 Hybrid AM system. The substrate was engineered to excite the second transverse bending vibration mode at 19.3 kHz. Additionally, a high-speed camera captured melt pool surface dynamics with and without sonication. In this talk, we will connect the effects of ultrasound on melt pool dynamics with microstructural development, detailing the roles of acoustic cavitation and streaming. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Solidification, Aluminum |