Design of Layered Metal Embedded Stress Sensing Structure and Testing of Microstructure and Properties in Ultrasonic Additive Manufacturing

doi:10.12382/bgxb.2023.0349

Abstract

Abstract:

A diaphragm type layered metal embedded stress sensing structure is proposed to address the issues of low accuracy and difficulty in detecting the internal stresses in metal structures using traditional patch testing. Material selection and structural design are carried out from aspects of the thickness of diaphragm layer and the material of diaphragm. Ultrasonic additive manufacturing is used to manufacture Cu/Al layered diaphragm structures. The mutual diffusion, phase composition, and microstructure of the diaphragm/substrate interface after ultrasonic consolidation are studied. Finite element impact simulation is used to simulate the strain of traditional patch structures and the layered embedded stress sensing structures obtained from manufacturing, Strain testing is conducted on layered embedded stress sensing structures to investigate the strain response effect of layered metal embedded stress sensing structures. The research results indicate that the shape of diaphragm designed by the diaphragm layer is a circular membrane, of which the film material is a pure copper with a film diameter of 20mm and a film thickness of 0.1mm. After ultrasonic additive manufacturing of Cu film/Al matrix, a small amount of Cu atoms diffuse towards the Al layer without generating new intermetallic compounds, forming a mechanically bonded toothed morphology. The results of impact simulation and strain testing both indicate that the strain response effect of the embedded stress sensing structure is more accurate than that of the traditional patch structure.

Key words: structural design, ultrasonic additive manufacturing, interface research, impact simulation

CLC Number:

TG453⁺.9

WANG Yu, BAI Shule, WANG Ziqi, LIU Bin, FENG Li, ZHAO Wenjuan, HAO Junhui. Design of Layered Metal Embedded Stress Sensing Structure and Testing of Microstructure and Properties in Ultrasonic Additive Manufacturing[J]. Acta Armamentarii, 2023, 44(12): 3783-3792.

Figures/Tables 21

Table 1 Parameters of 1060 aluminum, industrial pure titanium and, pure copper

名称	密度/ (kg·m^-3)	杨氏模量/GPa	剪切模量/GPa	体积模量/GPa	泊松比
1060铝	2770	71	26.692	69.608	0.33
工业纯钛	4620	120	35.294	114.29	0.36
纯铜	8900	110	41.045	114.58	0.34

Table 2 BF120-3AA150 strain gauge parameters

参数	数值
应变片尺寸(长×宽)/mm	6.9×3.9
栅丝尺寸(长×宽) /mm	3.0×2.0
应变片厚度/mm	0.02
应变片阻值/Ω	120
灵敏度/(mV·V^-1)	2.0
室温应变最值/(μm·m^-1)	20000
应变片材料	改性酚醛
栅丝材料	康铜箔,全封闭结构
适应温度/℃	-30~80

Fig.1 Modal analysis of natural frequency and stress distribution

Fig.2 Frequency response curves of two types of diaphragms

Fig.3 Frequency response curves of circular diaphragms of different materials

Table 3 The first-order resonant frequencies of diaphragms of three materials Hz

材料	理论计算值	有限元仿真值
1060铝	5077	5080
工业纯钛	4637	4640
纯铜	3667	3670

Fig.4 Frequency response curves of three circular diaphragms with different diameters

Fig.5 Strain gauge paste model

Table 4 Film shape, material, specification parameters of diaphragm

序号	名称	参数
1	形状类型	圆形
2	材料	铜
3	直径/mm	20
4	厚度/mm	0.1

Fig.6 Strain gauge paste model

Fig.7 Component design drawing

Fig.8 3D diagram of different styles of embedded stress sensing structure

Fig.9 Layered metal embedded stress sensing structural samples

Fig.10 Interface scan

Fig.11 Magnification scan

Fig.12 Patch type overall structure

Fig.13 Simulation geometric mesh model

Fig.14 Micro-strain cloud diagram of structure after loading

Fig.15 Micro-strain curves of different structures

Fig.16 Strain gauge voltage measurement diagram

Fig.17 Voltage waveforms of different loads

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