Ultrasonic Additive Manufacturing Process

Ultrasonic additive manufacturing is a solid-state joining method, which utilizes the basic principle of ultrasonic vibrations. Unique characteristics of the UAM techniques compared to existing AM techniques enables a wide range of application areas. This paper aims to comprehensively review ultrasonic additive manufacturing (UAM) process history, defects, process parameters, mechanical properties, application areas, challenges, and further research areas. There are two major defects, type-1 and type-2 associated with the UAM, and repairing of these defects via FSP has been presented. In this paper, the effect of various process parameters on the final built part and bonding strength has been discussed. In addition to that, major mechanical properties such as hardness, peel strength, shear strength, tensile strength, and fatigue strength have been addressed thoroughly. The future of the UAM, unique applications and limitations have been discussed.