NASA recently launched a new study called SBIR to study metals suitable for future cladding applications in the aerospace industry. Metal 3D printing company Fabrisonic uses its patented UAM (Ultrasonic Additive Manufacturing) process to fuse different amorphous alloys into multi-metal coatings to create a metal mixture with higher strength and corrosion resistance than ordinary crystalline alloys .
Fabrisonic's UAM technology is a hybrid metal 3D printing process that can ultrasonically weld a series of metal strips into a 3D shape. The method operates at low temperatures, which allows different materials (such as electronic devices) to be embedded in the metal alloy structure.
With the accumulation of metal objects, CNC machines can also be used to finish their inner and outer surfaces. Compared with traditional metal 3D printing processes, users can create more detailed shapes. Since the company applied for a patent for its UAM printing technology in 2017, it has been releasing its SonicLayer 1200 machine, which also has its UAM technology.
During the test, the research team found that the low temperature of UAM resulted in little or no intermetallic formation of dissimilar metal alloys, and did not reduce its high-strength characteristics. The two companies also discovered that multiple passes can be used to add more metal, which in turn allows the thickness of the structure to be tailored to the end use.
According to the paper, low ductility is usually a problem with existing crystalline alloys, but considering that UAM is compatible with multiple materials, it can add more ductile metals to the mixture. Similarly, traditional welding techniques limit BMG to specific geometries, but evaluations show that UAM can now be used to achieve more complex 3D shapes at a lower cost.
3D printed heat exchanger produced by Fabrisonic in cooperation with NASA
Overall, in the first phase of NASA's development plan, the partners managed to incorporate crystalline metals such as aluminum, titanium and steel to produce parts with a wall thickness of 1mm. In the future, 3D printing technology can be deployed in the creation of laminates for heavy equipment or insulating oil and gas pipelines.
The two companies stated in their paper: "LMGH and Fabrisonic can provide a generation of products and services that are more advanced than the current state-of-the-art technology. Significant advantages in substrate protection, extended service life and improved application efficiency provide market leverage means."