Microstructure and forming mechanism of metals subjected to ultrasonic vibration plastic forming: A mini review

Compared with traditional plastic forming,ultrasonic vibration plastic forming has the advantages of reducing the forming force and improving the surface quality of the workpiece.This technology has a very broad application prospect in industrial manufactur-ing.Researchers have conducted extensive research on the ultrasonic vibration plastic forming of metals and laid a deep foundation for the development of this field.In this review,metals were classified according to their crystal structures.The effects of ultrasonic vibration on the microstructure of face-centered cubic,body-centered cubic,and hexagonal close-packed metals during plastic forming and the mech-anism underlying ultrasonic vibration forming were reviewed.The main challenges and future research direction of the ultrasonic vibra-tion plastic forming of metals were also discussed.

A Wire-Driven Series Elastic Mechanism Based on Ultrasonic Motor for Walking Assistive System

In order to improve the elderly people's quality of life,supporting their walking behaviors is a promising technology.Therefore,based on one ultrasonic motor,a wire-driven series elastic mechanism for walking assistive system is proposed and investigated in this research.In contrast to tradition,it innovatively utilizes an ultrasonic motor and a wire-driven series elastic mechanism to achieve superior system performances in aspects of simple structure,high torque/weight ratio,quiet operation,quick response,favorable electromagnetic compatibility,strong shock resistance,better safety,and accurately stable force control.The proposed device is mainly composed of an ultrasonic motor,a linear spring,a steel wire,four pulleys and one rotating part.To overcome the ultrasonic motor's insufficient output torque,a steel wire and pulleys are smartly combined to directly magnify the torque instead of using a conventional gear reducer.Among the pulleys,there is one tailored pulley playing an important role to keep the reduction ratio as 4.5 constantly.Meanwhile,the prototype is manufactured and its actual performance is verified by experimental results.In a one-second operating cycle,it only takes 86 ms for this mechanism to output an assistive torque of 1.6 N·m.At this torque,the ultrasonic motor's speed is around 4.1 rad/s.Moreover,experiments with different operation periods have been conducted for different application scenarios.This study provides a useful idea for the application of ultrasonic motor in walking assistance system.

Mechanism and Kinetic Model of In-situ TiB_2/7055Al Nanocomposites Synthesized under High Intensity Ultrasonic Field

In-situ TiB2/7055Al nanocomposites are fabricated by in situ melt chemical reaction from 7055Al-K2TiF6-KBF4 system under high intensity ultrasonic field,and the mechanism and kinetic model of in-situ melt chemical reaction are investigated.X-ray diffraction （XRD） and scanning electron microscope （SEM） analyses indicate that the sizes of in-situ TiB2 nanoparticles are in the range of 80-120 nm.The results of ice-water quenched samples show that the whole process contains four stages,and the overall in-situ reaction time is 10 minutes.The in situ synthesis process is controlled mainly by chemical reaction in earlier stage （former 3 minutes）,and by the particulate diffusing in later stage.The mechanism of key reaction between Al3Ti and AlB2 under high intensity ultrasonic in the 7055Al-K2TiF6-KBF4 system is the reaction-diffusion-crack-rediffusion.Furthermore,the reactive kinetic models in 7055Al-K2TiF6-KBF4 system are established.

A Review on Ultrasonic-Assisted Forming:Mechanism,Model,and Process

Compared with conventional forming processes,ultrasonic-assisted forming technology with a high frequency and small amplitude can significantly improve the forming quality of materials.Owing to the advantages of reduced forming force,improved surface quality,avoidance of forming defects,and strengthened surface structure,ultrasonic-assisted forming technology has been applied to increasingly advanced forming processes,such as incremental forming,spinning,and micro-forming.However,in the ultrasonic-assisted forming process,there are multiple ultrasonic mechanisms,such as the volume effect and surface effect.The explanation of the effect of ultrasonic vibration(UV)on plastic deformation remains controversial,hindering the development of related technologies.Recently,many researchers have proposed many new theories and technologies for ultrasonic-assisted forming.To summarize these developments,systematic discussions on mechanisms,theoretical models,and forming performances are provided in this review.On this basis,the limitations of the current study are discussed.In addition,an outlook for ultrasonic-assisted forming is proposed:efficient and stable UV systems,difficulty forming components with complex geometry,explanation of the in-depth mechanism,a systematic theoretical prediction model,and multi-field-coupling energy-assisted forming are considered to be hot spots in future studies.The present review enhances existing knowledge of ultrasonic-assisted forming,and facilitates a fast reference for related researchers.

Interface microstructure and formation mechanism of ultrasonic spot welding for Al-Ti dissimilar metals

The present study focuses on interface microstructure and joint formation.AA6061 aluminum alloy(Al)and commercial pure titanium(Ti)joints were welded by ultrasonic spot welding(USW).The welding energy was 1100-3200 J.The Al-Ti joint appearance and interface microstructure were observed mainly via optical microscopy and field emission scanning electron microscopy.Results indicated that a good joint can be achieved only with proper welding energy of 2150 J.No significant intermetallic compound(IMC)was found under all conditions.The high energy barriers of Al-Ti and difficulties in diffusion were the main reasons for the absence of IMC according to kinetic analysis.The heat input is crucial for the material plastic flow and bonding area,which plays an important role in the joint formation.

Mechanism of ultrasonic-pulse electrochemical compound machining based on particles

The electric double layer with the transmission of particles was presented based on the principle of electrochemistry.In accordance with this theory,the cavitation catalysis removal mechanism of ultrasonic-pulse electrochemical compound machining(UPECM) based on particles was proposed.The removal mechanism was a particular focus and was thus validated by experiments.The principles and experiments of UPECM were introduced,and the removal model of the UPECM based on the principles of UPECM was established.Furthermore,the effects of the material removal rate for the main processing parameters,including the particles size,the ultrasonic vibration amplitude,the pulse voltage and the minimum machining gap between the tool and the workpiece,were also studied through UPECM.The results show that the particles promote ultrasonic-pulse electrochemical compound machining and thus act as the catalyzer of UPECM.The results also indicate that the processing speed,machining accuracy and surface quality can be improved under UPECM compound machining.

Bonding mechanism of ultrasonic wedge bonding of copper wire on Au/Ni/Cu substrate

The ultrasonic wedge bonding with d25 μm copper wire was achieved on Au/Ni plated Cu substrate at ambient temperature.Ultrasonic wedge bonding mechanism was investigated by using SEM/EDX,pull test,shear test and microhardness test.The results show that the thinning of the Au layer occurs directly below the center of the bonding tool with the bonding power increasing.The interdiffusion between copper wire and Au metallization during the wedge bonding is assumed negligible,and the wedge bonding is achieved by wear action induced by ultrasonic vibration.The ultrasonic power contributes to enhance the deformation of copper wire due to ultrasonic softening effect which is then followed by the strain hardening of the copper wedge bonding.

Mechanical properties of 2024-T4 aluminium alloy joints in ultrasonic vibration enhanced friction stir welding

Ultrasonic vibration enhanced friction stir welding （UVeFSW） is a recent modification of conventional friction stir welding （FSW）, which transmits ultrasonic vibration directly into the localized area of the workpiece near and ahead of the rotating tool. In this study, a high strength aluminium alloy （2024-T4） was welded by this process and conventional FSW, respectively. Then tensile tests, microhardness tests and fracture surface analysis were performed successively on the welding samples. The tests results reveal that ultrasonic vibration can improve the tensile strength and the elongation of welded joints. The microhardness of the stir zone also increases.

Metallographic structure,mechanical properties,and process parameter optimization of 5A06 joints formed by ultrasonic-assisted refill friction stir spot welding

Novel hybrid refill friction stir spot welding （RFSSW） assisted with ultrasonic oscillation was introduced to 5A06 aluminum alloy joints. The metallographic structure and mechanical properties of 5A06 aluminum alloy RFSSW joints formed without ultrasonic assistance and with lateral and longitudinal ultrasonic assistance were compared, and the ultrasonic-assisted RFSSW process parameters were opti- mized. The results show that compared with lateral ultrasonic oscillation, longitudinal ultrasonic oscillation strengthens the horizontal bond- ing ligament in the joint and has a stronger effect on the joint＇s shear strength. By contrast, lateral ultrasonic oscillation strengthens the ver- tical bonding ligament and is more effective in increasing the joint＇s tensile strength. The maximum shear strength of ultrasonic-assisted RFSSW 5A06 aluminum alloy joints is as high as 8761 N, and the maximum tensile strength is 3679 N when the joints are formed at a tool rotating speed of 2000 r/rain, a welding time of 3.5 s, a penetration depth of 0.2 mm, and an axial pressure of 11 kN.

Microstructure evolution and mechanical properties of the Sip/Zn- Al composite joints by ultrasonic-assisted soldering in air

Hypereutectic Al -27Si alloys were joined without flux by ultrasonic-assisted soldering at 420 ℃ in air using Zn -5Al the filler alloys, and Si particulate-reinforced Zn - Al based composites filler joints were obtained. The ultrasonic vibration introduced into soldering could influence the migration of Si particles and the microstructure of solidified Zn - Al based alloys. Both the distribution of Si particles and microstructure of the solidified Zn - Al based alloys affected the shear strength of joints. The shear strength increased with the ultrasonic vibration time. The highest average shear strength of joints reached to -68.5 MPa. Transcrystalline rupture mode was observed on the fracture surface.

Combined effects of ultrasonic vibration and manganese on Fe-containing inter-metallic compounds and mechanical properties of Al-17Si alloy with 3wt.%Fe

The research studied the combined effects of ultrasonic vibration (USV) and manganese on the Fe-containing inter-metallic compounds and mechanical properties of Al-17Si-3Fe-2Cu-1Ni (wt.%) alloys. The results showed that, without USV, the alloys with 0.4wt.% Mn or 0.8wt.% Mn both contain a large amount of coarse plate-like δ-Al4(Fe,Mn)Si2 phase and long needle-like β-Al5(Fe,Mn)Si phase. When the Mn content changes from 0.4wt.% to 0.8wt.% in the alloys, the amount and the length of needle-like β-Al5(Fe,Mn)Si phase decrease and the plate-like δ-Al4(Fe,Mn)Si2 phase becomes much coarser. After USV treatment, the Fe-containing compounds in the alloys are refined and exist mainly as δ-Al4(Fe,Mn)Si2 particles with an average grain size of about 20 μm, and only a small amount of β-Al5(Fe,Mn)Si phase remains. With USV treatment, the ultimate tensile strengths (UTS) of the alloys containing 0.4wt.%Mn and 0.8wt.%Mn at room temperature are 253 MPa and 262 MPa, respectively, and the ultimate tensile strengths at 350 °C are 129 MPa and 135 MPa, respectively. It is considered that the modified morphology and uniform distribution of the Fe-containing inter-metallic compounds, which are caused by the USV process, are the main reasons for the increase in the tensile strength of these two alloys.

Microstructures and mechanical properties of AZ80 alloy treated by pulsed ultrasonic vibration

Pulsed ultrasonic field was employed in the melt of the AZ80 magnesium alloy.The effects of pulsed ultrasonic field on microstructure and mechanical properties of AZ80 magnesium alloy were investigated.The results show that the as-cast microstructure of the AZ80 alloy with pulsed ultrasonic treatment is significantly changed.Pulsed ultrasonic field significantly decreases the grain size,changes the morphologies of theβ-Mg_(17)Al_(12) phases and reduces their area fraction.It is found that pulsc width of ultrasonic plays an important role on the microstructure formation of AZ80 alloy.With increasing pulse width,grains become finer and more uniform.In the range of experimental parameters,the optimum pulse width for melt treatment process is found to be 210μs.The mechanical tests show that the mechanical properties of the as-cast AZ80 magnesium alloy with pulsed ultrasonic treatment are much higher than those of AZ80 alloy without ultrasonic field.

Macrostructures and mechanical properties of ultrasonic-assisted friction stir welding joint of 2024-T3 aluminium alloy

In friction stir welding of aluminum alloys, tunnel defect may occur due to insufficient plastic material flow caused by lower heat input in the weld region. The inadequacy in heat input is due to improper selection of friction stir welding tool and process parameters. Ultimately, such defects degrade the properties of weld and may pose serious concerns towards the integrity and safety of the weld component. In order to improve the properties of weld joints, an ultrasonic-assisted friction stir welding device has been configured where ultrasonic energy is transferred from an ultrasonic unit directly into one of the workpieces near the tool. Using this configuration, ultrassonic-assisted friction stir welding was conducted on 6 mm thick 2024- 73 aluminum alloy sheets. The macrostructure and mechanical properties of these welds were compared with the welds of this alloy prepared by conventional friction stir welding using identical process parameters. The results show that the welding speed can be increased while satisfactory weld quality is still ensured. The ultrasonic energy transferred in this configuration could enlarge the volume of weld nugget zone. Also, the influence of ultrasonic energy on the suppression or elimination of the tunnel defect is quite apparent. However, any beneficial effects of ultrasonic vibration on the tensile strength and the elongation of the joint were less obvious in this configuration.

Ultrasonic Welding of Magnesium–Titanium Dissimilar Metals:A Study on Thermo-mechanical Analyses of Welding Process by Experimentation and Finite Element Method

Ultrasonic welding is an effective ways to achieve a non-reactive/immiscible heterogeneous metal connection, such as the connection of magnesium alloy and titanium alloy. But the thermal mechanism of magnesium alloy/titanium alloy ultrasonic welding has not been defined clearly. In this paper, the experimental and the finite element analysis were adopted to study the thermal mechanism during welding. Through the test, the temperature variation law during the welding process is obtained, and the accuracy of the finite element model is verified. The microscopic analysis indicates that at the welding time of 0.5 s, the magnesium alloy in the center of the solder joint is partially melted and generates the liquid phase. Through the finite element analysis, the friction coefficient of the magnesium–titanium ultrasonic welding interface can be considered as an average constant value of 0.28. The maximum temperature at the interface can exceed 600 ℃ to reach the melting point temperature of the magnesium alloy. The plastic deformation begins after 0.35 s and occurs at the magnesium side at the center of the interface.

Research on ultrasonic-based investigation of mechanical properties of ice

Arctic sea ice area and thickness have declined dramatically during the recent decades.Sea ice physical and mechanical properties become increasingly important.Traditional methods of studying ice mechanical parameters such as ice-coring cannot realize field test and long-term observation.A new principle of measuring mechanical properties of ice using ultrasonic was studied and an ultrasonic system was proposed to achieve automatic observation of ice mechanical parameters(Young’s modulus,shear modulus and bulk modulus).The ultrasonic system can measure the ultrasonic velocity through ice at different temperature,salinity and density of ice.When ambient temperature decreased from 0°C to-30°C,ultrasonic velocity and mechanical properties of ice increased,and vice versa.The shear modulus of the freshwater ice and sea ice varied from 2.098 GPa to 2.48 GPa and 2.927 GPa to 4.374 GPa,respectively.The bulk modulus of freshwater ice remained between 3.074 GPa and4.566 GPa and the sea ice bulk modulus varied from 1.211 GPa to 3.089 GPa.The freshwater ice Young’s modulus kept between 5.156 GPa and 6.264 GPa and sea ice Young’s modulus varied from 3.793 GPa to 7.492 GPa.The results of ultrasonic measurement are consistent with previous studies and there is a consistent trend of mechanical modulus of ice between the process of ice temperature rising and falling.Finally,this ultrasonic method and the ultrasonic system will help to achieve the long-term observation of ice mechanical properties of ice and improve accuracy of sea ice models.

Effect of ultrasonic assisted sintering on mechanical properties and degradation behaviour of Mg15Nb3Zn1Ca biomaterial

The present work investigates the effect of ultrasonic power(%)and the time of ultrasonic vibration on the sintered density and ultimate compressive strength(UCS)of Mg15Nb3Zn1Ca fabricated using ultrasonic assisted conventional sintering(UACS).The customized UACS setup was designed and manufactured to conduct the experimentations.A customized ultrasonic stepped horn assembly was used for providing vibrations to the sample during sintering.Further,to evaluate the efficacy of ultrasonic vibration parameters,the developed setup was used to sinter Mg15Nb3Zn1Ca composite material.The study unveiled an increased sintered density and UCS of the fabricated sample by the increase in ultrasonic power(%).Moreover,a decrease in sintered density and UCS was observed with an increase in the time of ultrasonic vibration beyond a certain limit.Samples sintered with the assistance of ultrasonic vibration at 100%ultrasonic power,and 20 min of ultrasonic vibration resulted in a sintered density of 1.928±0.062 g·cm^(-3)and UCS of 234.9±12.3 MPa.The obtained mechanical properties of the fabricated sample were comparable to the properties of cortical bone.The surface morphology and elemental compositions of samples fabricated using UACS declared a fair dispersion of reinforcement in the matrix containing merely the source elements.The results of corrosion test have showed that the assistance of ultrasonic vibration suppressed the degradation behaviour of the sintered sample after performing electrochemical study of samples using 3-electorde cell voltammetry.Mg15Nb3Zn1Ca fabricated using UACS showed a 50.18%and 9.08%of reduction in corrosion rate over conventionally sintered pure Mg and Mg15Nb3Zn1Ca respectively.In addition,electrochemical impedance spectroscopy(EIS)results indicated an enhanced corrosion resistance of the Mg15Nb3Zn1Ca composite material when fabricated at 100%of ultrasonic power with 20 min of vibration time.Apart from that,electrochemical equivalent circuits also resulted in good fitting of the experimental data obtained from EIS.

Ultrasonic Mechanical, Dialectical and Morphology Characterizations of Unsaturated Copolyesters and Terpolyesters

In a previous study we focused on the synthesis of new family of unsaturated copolyesters and terpolyesters by interfacial condensation polymerization. Here, in this study as complementary work of physical characterizations, we focused on the morphological features using X-ray and SEM investigation. Further, the mechanical properties of solid polymers were also studied by a new technique echo-pulse using ultrasonic impulses. This technique was used for solid polymers to determine the elastic moduli involving, Young’s modulus, shear modulus, bulk modulus and micro-hardness modulus. The statistical relation between different kinds of copolyesters and terpolyesters with Poisson’s ratio (υ) and micro-hardness were shown. The dielectric constant (?) and the electrical resistance (Rp) of the solid copolyesters and terpolyesters including aliphatic, aromatic and azo group in the main chain have been studied at room temperature. Moreover, the relation between frequency and dielectric constant for the selective polymers has been also illustrated.

Effects of Ultrasonic Treatment on Microstructure and Mechanical Properties of Semisolid Sn-52Bi Alloy

The effects of ultrasonic vibration temperature on the microstructure of semisolid Sn-52 Bi alloy and mechanical properties were investigated. The results show that the microstructure and mechanical properties are improved obviously after the ultrasonic treatment. Nearly round and uniformly distributed primary Sn phase particles were obtained under the cavitation and acoustic streaming caused by ultrasonic treatment. The best effects of ultrasonic treatment on microstructure and mechanical properties were obtained with the ultrasonic vibration for 120 s at 140 ℃. The elongation of semisolid Sn-52 Bi alloy treated by ultrasonic vibration for 120 s at 140 ℃ was 42% and increased by 156.09% compared to conventional liquid casting Sn-52 Bi alloy without ultrasonic vibration. It is a feasible and effective method to adopt the semisolid metal forming technology assisted with ultrasonic vibration to improve the ductility of Sn-Bi alloys.

Effects of Ultrasonic Waves during Resin Impregnation on the Mechanical Properties of Unidirectional Composite Materials

Effects of ultrasonic vibrations on mechanical properties of fiber reinforced plastics were investigated during molding resin impregnation process in vacuum assisted resin transfer molding.?The vacuum bag including the preformed each?non-crimp fabrics (carbon and glass fibers)?was placed in a water bath of an ultrasonic wave generator during resin impregnation. The mechanical properties of the laminates were evaluated?through the mechanical strength tests and scanning electron microscope?(SEM) observation. The results revealed that ultrasonic waves improved transverse tensile, flexural, interlaminar shear, and compressive strengths of the carbon fiber (CF) laminates and interlaminar shear and compressive strengths of the glass fiber (GF) laminates. It was found from SEM observation that the fracture modes of the CF and GF laminates processed using ultrasonic waves were resin fracture. Accordingly, the adhesion of the fiber/resin interface was improved by oscillating ultrasonic vibration during resin impregnation, leading to an increase of the interface strength.

Inverse Problems in Solid Mechanics and Ultrasonic

在稳固的力学的 IP (反的问题) 整个第 20 世纪出现了并且测量。现在有在稳固的力学接受反的问题的分类[1 ] ：回顾的 IP，边界 IP，系数 IP，几何 IP。在弹性的理论的 IP，粘性的理论，加强的理论，疲劳理论，多晶的材料的破裂理论微结构被提出并且解决。超声的波浪的高频率理论的方法被使用。这里被获得的结果出现，所有系数和在材料的瑕疵的几何特征超声的波浪的纵、横过的速度和变细仅仅是功能，它被测量， ASTM E 494：2015。从这篇文章的收到的关系能在多晶的材料被用于系数的 NDE (非破坏性的评估) 和瑕疵的几何特征。