Ultrasonic Consolidation (UC) is a new welding process that permits unique and advanced part fabrication. Using a continuous, rolling process, layers of metal material can be welded together to encapsulate a variety of devices and geometries, including in situ strain sensors, thermocouples and conformal cooling channels. Together, these strengths can be combined to build smart, lightweight structures excellent for use in aerospace applications sensitive to weight and corrosivity.
This talk will discuss the fundamental processes and strengths of UC for creating these structures. Key components include the materials science associated with ultrasonic excitation, deformation and fabrication capabilities of the Solidica welding platform. Examples of in situ component embedding will be highlighted and a final case study presented.