An investigation into using laser micro channelling to assist fibre integration via Ultrasonic Consolidation

Ultrasonic Consolidation (UC) is a layer-by-layer metal-based additive manufacturing process. Bonding between two layers is accomplished by energy transmission in form of ultrasonic oscillations inducing localised plastic deformation. The benefit of localised plastic deformation and bonding below melting temperatures has been effectively used for fibre integration. Thus, UC presents a feasible alternative to other metal-manufacturing processes as well as an attractive method for novel engineering materials production such as smart structures.Yet, high volume fibre embedding has been shown to result in delamination of foils and greater porosity at the bonding interfaces due to insufficient plastic flow around the fibres. Furthermore, post-functionality of delicate fibre types was limited. In this study a novel hybrid approach aiming to reduce the necessary plastic flow around fibres and high fibre volume embedding is presented. [Continues.]