A Complete Review of Ultrasonic Metal Welding, Ultrasonic Consolidation, and Additive Manufacturing Techniques

Abstract

For joining standardized metals and alloys, conventional fusion-based welding methods like electron beam welding (EBW), laser beam welding (LBW), friction stir spot welding (FSSW), and resistance spot welding (RSW) are frequently employed. Nevertheless, these procedures frequently experience uneven weld quality, thermal distortion, and metallurgical degradation because of high processing temperatures. Solid-state joining technologies, especially ultrasonic consolidation (UC) and ultrasonic additive manufacturing (UAM), have been developed as a result of these constraints. In order to create metallurgical bonds between metallic or non-metallic foils at almost room temperature, UC/UAM uses high-frequency ultrasonic vibrations under moderate normal pressure. This allows for the creation of low-temperature, multi-layered solid structures without melting the base materials.