Micro-Scale Gold Ultrasonic Additive Manufacturing Method And Experimental Research

Gold has excellent conductivity,corrosion resistance,and catalytic properties,making it widely used in engineering fields such as biomedicine,aerospace,metal catalysts,and electronic communication.With the urgent demand for gold materials in emerging fields such as new energy,environmental protection,3D printing,and new materials,it is necessary to continue researching and developing new gold forming and manufacturing processes.In this paper,we developed a micro-scale gold ultrasonic additive manufacturing method and proposed important manufacturing size parameters during the manufacturing process: center distance of cutting gold wire,cumulative spacing,and transient parameters: ultrasonic time,ultrasonic power and pressure,as well as the concept of half subsidence body.We revealed the formation mechanism and control mechanism of macro-micro defects in the process of forming gold from points to lines,surfaces,and bodies by manufacturing process parameters.Finally,we achieved optimized design of gold block ultrasonic additive manufacturing.The specific research contents are as follows:(1)Developed a micro-scale gold ultrasonic additive manufacturing device and used a high-speed camera to investigate the transient changes during the manufacturing process.Two key manufacturing size parameters,center distance of cutting gold wire and cumulative spacing,were proposed and the deposition state of the half subsidence body and the mechanism of single point deposition were analyzed.Single-point deposition experiments were carried out using the micro-scale gold ultrasonic additive manufacturing device to explore the relationship between the center distance of cutting gold wire and macro-micro morphology of single-point deposition,providing guidance for subsequent 2D and 3D depositions.(2)The influence mechanism of process parameters on the formation of twodimensional deposition structures,such as lines and surfaces,was studied,and the macro-micro morphology of the formed structures was analyzed using electron and super depth microscopes.The effects of different printing directions and cumulative spacing on the macro-micro morphology of the line deposition structure were explored,and the mechanism of defect formation was analyzed,providing parameter references for subsequent experiments.Common problems in additive manufacturing,such as the staircase effect,can occur in surface-type structures.Based on the micro-scale ultrasonic additive manufacturing principle,the effects of cumulative spacing and center distance of cutting gold wire on the surface morphology and formation mechanism of the staircase effect for surface structures were studied.Using orthogonal experiments,the influence mechanism of transient process parameters,such as ultrasonic time,ultrasonic power,and pressure,on the formation of defects was revealed.(3)The influence mechanism of manufacturing size parameters on the gold block structure in ultrasonic additive manufacturing was studied.Based on layer-by-layer accumulation experiments,the manifestation of the staircase effect on threedimensional deposition bodies was further observed using a super depth microscope.Regularities were summarized,and a method for optimizing the experimental design was proposed.The influence of the application times of ultrasonic energy on the hardness of gold was studied using nano-indentation experiments.Different printing paths were designed to try to improve the staircase effect.The morphology characteristics of the deposited blocks on each printing path were analyzed,and the optimal printing path was explored.The deposition effect was further optimized by improving the cutting gold wire strategy and cumulative spacing.Finally,CT scans were analyzed to reveal internal structural characteristics and porosity properties.