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Unveiling the potential of ultrasonic-based processes: pioneering the next frontier in aerospace sensing materials manufacturing

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Resumo:Ultrasonic consolidation (UC) is a layer-by-layer manufacturing process in which thin metal foils are joined through the combined effects of compressive forces and ultrasonic oscillations. This process involves a complex bond formation mechanism comprising multiple phenomena that ultimately determine the final mechanical properties of the part. Extensive experimental research has been conducted to study the properties of samples produced through UC using different materials andprocessing conditions. Although less common, some researchers have also attempted to model the UC process and predict mechanical properties using numerical simulation. This work aims to study the integration of piezoelectric sensors into aerospace structures using the UC process. The primary goal is to investigate how UC can enable the sensitization of aerospace structures, as very few studies have explored the use of such sensors. A numerical model of the process was first developed to understand the mechanisms behind bond formation. With this foundation, a specialized machine was designed and built to perform the process and conduct experimental tests. The numerical model is is used as an optimizing tool for the experimental procedure by identifying optimal process parameters, reducing the need for extensive trial-and-error testing. Results from the thermomechanical model formulated to simulate the UC process agree with those observed in numerical models from the literature. The designed UC prototype consisted of three subassemblies, one of which responsible for applying the ultrasonic oscillations and normal forces, through a pneumatic cylinder. A second subassembly includes the worktable system, which includes the X and Y-axis translation systems driven by trapezoidal screws and stepper motors, along with the machine's frame.The prototype operation was experimentally validated,and the results from the process were obtained.
Autores principais:Pereira, Bruno Miguel Oliveira
Assunto:Ultrasonic consolidation Numerical simulation Mechanical properties Aerospace applications Sensing materials Consolidação por ultrassons Simulação numérica Propriedades mecânicas Estruturas aeroespaciais Materiais sensorizados Engenharia e Tecnologia::Engenharia Mecânica
Ano:2024
País:Portugal
Tipo de documento:dissertação de mestrado
Tipo de acesso:acesso aberto
Instituição associada:Universidade do Minho
Idioma:inglês
Origem:RepositóriUM - Universidade do Minho

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