Systems and methods for joining and repair using ultrasonic additive manufacturing with a contoured sonotrode

Patent metadata

Field	Value
Publication number	US-11697172-B2
Application number	US-202017013128-A
Country	US
Kind code	B2
Filing date	Sep 4, 2020
Priority date	Sep 5, 2019
Publication date	Jul 11, 2023
Grant date	Jul 11, 2023

Abstract

An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.

First claim

What is claimed is:

1. An ultrasonic additive manufacturing system comprising:
a base structure;
a sonotrode configured to rotate about an axis of rotation, wherein the sonotrode comprises a welding surface extending along a circumference of the sonotrode, wherein the welding surface has a V-shaped profile and a first side and a second side disposed opposite one another in a direction of the axis of rotation, wherein the welding surface has a central plane disposed between the first side and the second side in the direction of the axis of rotation, wherein the central plane extends perpendicular to the axis of rotation of the sonotrode and is centered with respect to the welding surface in the direction of the axis of rotation, wherein the welding surface has a maximum diameter located in the central plane, and wherein at least one of the sonotrode and the base structure is configured to translate relative to the other of the sonotrode and the base structure; and
one or more transducers configured to vibrate the sonotrode.

2. The ultrasonic additive manufacturing system of claim 1 , wherein the V-shaped profile is defined by a first side portion and a second side portion of the welding surface.

3. The ultrasonic additive manufacturing system of claim 1 , wherein the V-shaped profile further comprises a curved profile defined by a central portion of the welding surface disposed between a first side portion and a second side portion of the welding surface.

4. The ultrasonic additive manufacturing system of claim 1 , wherein the V-shaped profile is symmetric about the central plane.

5. The ultrasonic additive manufacturing system of claim 1 , wherein the welding surface comprises a surface texture.

6. The ultrasonic additive manufacturing system of claim 1 , wherein the V-shaped profile is defined by a first side portion and a second side portion of the welding surface, and wherein the V-shaped profile is formed such that the first side portion and the second side portion of the welding surface converge at a point along the central plane of the welding surface.

7. The ultrasonic additive manufacturing system of claim 1 , wherein the V-shaped profile has an included angle between 60 degrees and 179 degrees.

8. The ultrasonic additive manufacturing system of claim 1 , wherein the welding surface extends along an entirety of the circumference of the sonotrode.

9. The ultrasonic additive manufacturing system of claim 8 , wherein a shape of the V-shaped profile is the same along the entirety of the circumference of the sonotrode.

10. The ultrasonic additive manufacturing system of claim 1 , wherein a diameter of the welding surface varies along the first side and the second side in a direction of the axis of rotation.

11. The ultrasonic additive manufacturing system of claim 1 , wherein the at least one of the sonotrode and the base structure is configured to translate relative to the other of the sonotrode and the base structure in a direction perpendicular to the axis of rotation of the sonotrode.

12. The ultrasonic additive manufacturing system of claim 1 , wherein the one or more transducers are configured to vibrate the sonotrode in a direction of the axis of rotation of the sonotrode.

Assignees

• Ohio State Innovation Foundation

Inventors

• DAPINO Marcelo
• Headings Leon
• Gingerich Mark

Classifications

• B23P6/00

  Restoring or reconditioning objects (straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10) · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B23K20/106 Primary

  Features related to sonotrodes · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B23K20/103

  using a roller · CPC title