Method for using soluble sacrificial materials in ultrasonic additive manufacturing
View Patent ↗A method of ultrasonic additive manufacturing comprising using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape; machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits; depositing a sacrificial support material in the internal features, wherein the sacrificial support material includes at least one water-soluble solid, and at least one water-soluble binding agent; curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features; using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial material and solid metal object to complete the solid metal object; and introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefrom.
1. A method for ultrasonic additive manufacturing, comprising:
(a) using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape;
(b) machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits;
(c) depositing a sacrificial support material in the internal features, wherein the sacrificial support material includes at least one water-soluble solid, and at least one water-soluble binding agent;
(d) curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features;
(e) using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial support material and solid metal object to complete the solid metal object;
(f) introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefrom; and
(g) machining channels or other features into the sacrificial support material for facilitating extraction thereof from the completed solid metal object.
2. The method of claim 1 , wherein the sacrificial support material further comprises a stiffening component, wherein the stiffening component includes at least one powdered metal.
3. The method 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 method of claim 1 , wherein the water-soluble solid is a sodium salt.
5. The method of claim 1 , wherein the water-soluble binding agent is a synthetic polymer.
6. The method of claim 1 , wherein the water-soluble binding agent is polyvinyl alcohol.
7. The method 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 method for ultrasonic additive manufacturing, comprising:
(a) using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape;
(b) machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits;
(c) depositing a sacrificial support material in the internal features,
(i) wherein the sacrificial support material includes at least one water-soluble solid further comprising a salt; and
(ii) at least one water-soluble binding agent further comprising polyvinyl alcohol;
(d) curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features;
(e) using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial support material and solid metal object to complete the solid metal object;
(f) introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefrom; and
(g) machining channels or other features into the sacrificial support material for facilitating extraction thereof from the completed solid metal object.
9. The method of claim 8 , wherein the sacrificial support material further comprises a stiffening component, wherein the stiffening component includes at least one powdered metal.
10. The method of claim 8 , 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.
11. The method of claim 8 , 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.
12. A method for ultrasonic additive manufacturing, comprising:
(a) using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape;
(b) machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits;
(c) depositing a sacrificial support material in the internal features,
(i) wherein the sacrificial support material includes at least one water-soluble solid further comprising a salt; and
(ii) at least one water-soluble binding agent further comprising polyvinyl alcohol;
(d) curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features;
(e) machining channels or other features into the sacrificial support material for facilitating extraction thereof from the solid metal object after completion thereof;
(f) using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial support material and solid metal object to complete the solid metal object; and
(g) introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefrom.
13. The method of claim 12 , wherein the sacrificial support material further comprises a stiffening component, wherein the stiffening component includes at least one powdered metal.
14. The method of claim 12 , 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.
15. The method of claim 12 , 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.