Optimized Process for Ultrasonic Consolidation of Metallic Composites

The overall objective of the proposed effort is to develop an improved ultrasonic consolidation (UC) process for metal matrix composites (MMCs). The Phase I effort demonstrated the feasibility of using a fiber-matrix unit cell finite element analysis to study the thermal and acoustic softening that occurs during UC. The analyses completed in Phase I highlighted the need for uniform prepreg material and appropriate anvil knurl patterns in order to optimize the UC process. These factors will become the focus of the Phase II effort with production of relevant test articles and laminated structures to be carried out once the tape uniformity and UC process have been optimized. Touchstone Research Laboratory (Touchstone) will team with the University of Delawares Center for Composite Materials (UD-CCM) again during the Phase II effort. Touchstone will be the producer of the improved MetPreg prepreg tape and will perform testing and characterization of the feedstock material and finished components. UD-CCM will continue its modeling work and will also produce the bonded specimens and structures using its UC equipment.