SOLUBLE SACRIFICIAL MATERIALS FOR USE IN ULTRASONIC ADDITIVE MANUFACTURING

1 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:

(a) at least one water-soluble solid; and

(b) at least one water-soluble binding agent,

(c) wherein the at least one water-soluble solid is mixed with the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.

2 . The sacrificial material of claim 1 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one powdered metal, sand, or combinations thereof.

3 . The sacrificial material of claim 1 , wherein ratio of the at least one water-soluble solid to the at least one water-soluble binding agent is five parts water-soluble solid to one part water-soluble binding agent, by volume.

4 . The sacrificial material of claim 1 , wherein the water-soluble solid is a sodium salt, a potassium salt, an ammonium salt, or combinations thereof.

5 . The sacrificial material of claim 1 , wherein the water-soluble binding agent is a synthetic polymer.

6 . The sacrificial material of claim 1 , wherein the water-soluble binding agent is polyvinyl alcohol, polyvinyl acetate, or a combination thereof.

7 . The sacrificial material of claim 1 , wherein the predetermined temperature is within the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours.

8 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:

(a) a water-soluble solid; and

(b) a water-soluble binding agent, wherein the water-soluble binding agent includes a synthetic polymer, wherein the synthetic polymer is polyvinyl alcohol or polyvinyl acetate, and

(c) wherein the water-soluble solid is mixed with the water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.

9 . The sacrificial material of claim 8 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one powdered metal, sand, or combinations thereof.

10 . The sacrificial material of claim 8 , wherein ratio of the water-soluble solid to the water-soluble binding agent is five parts water-soluble solid to one part water-soluble binding agent, by volume.

11 . The sacrificial material of claim 8 , wherein the water-soluble solid is a sodium salt, a potassium salt, an ammonium salt, or combinations thereof.

12 . The sacrificial material of claim 8 , wherein the predetermined temperature is in the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours.

13 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:

(a) a solid, wherein the solid is sodium chloride; and

(b) a binder, wherein the binder is polyvinyl alcohol, and

(c) wherein the solid is mixed with the binder and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.

14 . The sacrificial material of claim 13 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one metal powder, sand, or combinations thereof.

15 . The sacrificial material of claim 13 , wherein ratio of the solid to the binder is five parts solid to one part binder, by volume.

16 . The sacrificial material of claim 13 , wherein the solid is water soluble.

17 . The sacrificial material of claim 13 , wherein the binder is water soluble.

18 . The sacrificial material of claim 13 , wherein the predetermined temperature is in the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours.