Restricted accessResearch articleFirst published online 2025-3
Analytical model for estimation of interface weld strength in ultrasonic additive manufacturing (UAM) of similar and dissimilar tempered aluminum alloy 6061 (AA6061)
Process modeling of ultrasonic additive manufacturing (UAM) is critical for optimizing process settings with minimal experimental trials. In this research, a parameter termed weld quality (Qw) is formulated based on hardness and process settings to predict the shear strength of aluminum alloy 6061 (AA6061) UAM weld interfaces between similar and dissimilar tempers. Four AA6061 tempers are investigated: O (annealed), H18 (cold rolled with 75% thickness reduction), T4 (solution heat treated and naturally aged), and T6 (solution heat treated and artificially aged). Shear samples quantify the shear strength at foil-to-foil and baseplate-to-foil interfaces, with near-gapless bonding observed. The Qw parameter linearly correlates with shear strength measurements, achieving a coefficient of determination () of 91.18%.
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