Ultrasonic Rapid Manufacturing of Meso/Microscale Functional and Active Structures

超声快速制造介观/微米级功能和活性结构

• 批准号: 0114309
• 负责人: Peter Wong
• 金额: --
• 依托单位: Tufts University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2001
• 资助国家: 美国
• 起止时间: 2001-09-01 至 2006-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0114309&HistoricalAwards=false
• 关键词: Ultrasonic; Rapid; Manufacturing; Meso; Microscale; Ultrasonic; Rapid; Manufacturing; Meso; Microscale

This program will introduce and analyze a new rapid manufacturing technology for fabrication of functional miniature devices with integrated intelligent structures and encapsulated components. This will be based on the ultrasonic welding (USW) process, a solid-state, cold joining technique, yielding strong bonding between dissimilar metals and other materials. Ultrasonic rapid manufacturing (URM) will utilize multiple material foils and fibers, that will be bonded in subsequent layers, followed by ultrasonically assisted diamond scribing to the proper contours. Fundamental understanding and comprehensive modeling of microscale USW, will be addressed by a hybrid experimental and computational process analysis. Extensive characterization of the joint structure and properties of aluminum bonds to other selected metal alloys will be performed in the laboratory. Knowledge gained from this research will define optimal process conditions, allow intensive study of microscale material effects, making it accessible through incorporation in a continuous ultrasonic transformation database. Numerical simulation of the interdependent mechanical, thermal and diffusion distributions during the USW process will be conducted in concert with the experimental work. Researchers at Tufts University and Northeastern University will collaborate on this project.This URM research will be connected with the engineering curriculum to leverage rapid manufacturing education. This will be promoted by a new undergraduate/graduate course on Rapid Prototyping, Tooling and Manufacturing, as a basis for a future Rapid Manufacturing minor; a new SFF and Microfabrication Seminar series with invited industry experts; and an annual Rapid Manufacturing Contest for undergraduate student groups nationwide. The program will involve close collaboration of the partnering institutions. Industrial sponsorship through in-kind equipment and technical support will also be provided by Axcelis Technologies, Honda R&D Americas and Stapla Ultrasonics. The benefits of the new technology will be harnessed in the design and fabrication of miniature multi-material internal structures, with embedded prefabricated elements (sensors, actuators, processors, MEMS etc), providing multi-domain functionality in mechatronic, optoelectronic, microfluidic, biomedical microdevices etc.

该计划将介绍和分析一种新的快速制造技术，用于制造具有集成的智能结构和封装组件的功能微型设备。这将基于超声焊接（USW）工艺，一种固态，冷的连接技术，在不同的金属和其他材料之间产生牢固的键合。超声波快速制造（URM）将利用多种材料箔和纤维，这些材料箔和纤维将在随后的层中粘合，然后进行超声辅助的钻石涂鸦，以适当的轮廓。 Microscale USW的基本理解和全面建模将通过混合实验和计算过程分析来解决。将在实验室中对铝键与其他选定金属合金的关节结构和特性进行广泛表征。从这项研究中获得的知识将定义最佳过程条件，可以深入研究显微镜材料效应，从而可以通过在连续的超声转换数据库中融合来访问它。在USW过程中，将与实验工作一起进行相互依存的机械，热和扩散分布的数值模拟。塔夫茨大学和东北大学的研究人员将在该项目上进行合作。该URM研究将与工程课程相关，以利用快速的制造教育。这将由新的本科/研究生课程促进快速原型制造，工具和制造业，作为未来快速制造次要的基础；由邀请行业专家进行的新的SFF和微型制作研讨会系列；以及全国本科生的年度快速制造竞赛。该计划将涉及合作机构的密切合作。 Axcelis Technologies，Honda R＆D Americas和Stapla Ultrasonics也将通过实物设备和技术支持通过工业赞助。新技术的好处将在微型多物质内部结构的设计和制造中得到利用，并具有嵌入式预制元素（传感器，执行器，处理器，MEMS等），可在机电，光电，微荧光，生物胶体微型微型胶片等中提供多域功能。