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Developments in Advanced Manufacturing Techniques: Impact Welding and Metamorphic Manufacturing

Thurston, Brian Patrick
http://orcid.org/0000-0002-2917-6056
http://rave.ohiolink.edu/etdc/view?acc_num=osu1689951299143669

Abstract Details

2023, Doctor of Philosophy, Ohio State University, Materials Science and Engineering.
The work in this dissertation is focused on the development of new manufacturing technologies at the early stage. Two concepts are developed in the category of Impact Welding and two in the category of Metamorphic Manufacturing. Under the Impact Welding category two different welding processes are studied, the Vaporizing Foil Actuator Welding and the Augmented Laser Impact Welding processes. Both of these processes were demonstrated to produce impact welds between traditionally unweldable aircraft aluminum alloys which performed as well or better than comparable riveted joints without the need for the drilling of holes or removal of surface coatings. Additionally, basic engineering guidelines are established for the design of foils for the Vaporizing Foil Actuator Welding process and basic performance metrics are established for the Augmented Laser Impact Welding technique. Two new data analysis techniques were developed for the Augmented Laser Impact Welding process which were validated by the use of high-speed videography. Models of the impact conditions for both of these impact welding techniques were established. For the Augmented Laser Impact Welding process, a technique for accurately measuring the welding velocity during an impact event is developed and validated. Metamorphic Manufacturing refers to the agile use of deformation to create shapes and modify microstructure. In this area two concepts were developed where metallic components are transformed from one shape into a second more desirable and useful form. A device and process for bending medical fixation plates to match patient skeletal anatomy is developed. The method can make arbitrary controlled shapes and may save time in the operating room for reconstruction surgeries. The second concept is an approach for Robotic Blacksmithing, a process for incrementally transforming a malleable material into useful shapes by deformation. This concept was initially developed on a purpose-built desktop robotic system. Once successfully demonstrated at small scale, Robotic Blacksmithing was then used to produce an aluminum part which closely resembled the target geometry, albeit with some limitations. This Robotic Blacksmithing process may complement CNC machining and 3D printing as a common manufacturing technique.
Glenn Daehn (Advisor)
Antonio Ramirez (Committee Member)
Boyd Panton (Committee Member)
Enam Chowdhury (Committee Member)
258 p.
Materials Science; Medicine; Robotics
Impact Welding Vaporizing Foil Actuator Welding VFAW Laser Impact Welding LIW Augmented Laser Impact Welding Metamorphic Manufacturing Photon Doppler Velocimetry PDV Profilometry Pin Contact Method Robotic Blacksmithing Point of Care Manufacturing

Recommended Citations

Citations

  • Thurston, B. P. (2023). Developments in Advanced Manufacturing Techniques: Impact Welding and Metamorphic Manufacturing [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1689951299143669

    APA Style (7th edition)

  • Thurston, Brian. Developments in Advanced Manufacturing Techniques: Impact Welding and Metamorphic Manufacturing. 2023. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1689951299143669.

    MLA Style (8th edition)

  • Thurston, Brian. "Developments in Advanced Manufacturing Techniques: Impact Welding and Metamorphic Manufacturing." Doctoral dissertation, Ohio State University, 2023. http://rave.ohiolink.edu/etdc/view?acc_num=osu1689951299143669

    Chicago Manual of Style (17th edition)

osu1689951299143669
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© 2023, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.