Additive Manufacturing

Laser Assisted 3D Metal Printing

Aim of this work is to understand the effect of scan speed, laser power, environment temperature, and scan pattern on the induced residual stresses and distortion with in the component. Also to develop a computational methodology to simulate microstructure evolution during laser melting and solidification to understand its effect on macroscale residual stresses and distortion.

Ultrasonic Consolidation

Ultrasonic consolidation process is a rapid manufacturing process used to weld thin layers of metals at low temperatures and low energy consumption. Experimental results have shown that ultrasonic consolidation is a combination of both surface (friction) and volume (plasticity) softening effects. In this work, a first attempt to simulate the ultrasonic consolidation of metals by taking into account both effects (surface and volume) at various length-scales. Comparison of the simulation results with experimental results shows similar behaviour.

It was also investigated that how different kinds of fibre and sensors can be embedded in different alloys using ultrasonic consolidation process. Also, how these embedding processes can be simulated and then optimized.

Related Animations:

– Acoustic Softening Phenomenon during Ultrasonic Consolidation Process– Ultrasonic Consolidation of Monolithic Structure– Dynamic Yielding during UC Fibre Embedding– Temperature Evolution during UC Fibre Embedding

Residual Stress Evolution during Selective Laser Melting Process

Fibre Embedding via Ultrasonic Consolidation

Selected Publications

A. Siddiq, E. Ghassemieh, Thermomechanical Analyses of Ultrasonic Welding Process using Thermal and Acoustic Softening Effects, Mechanics of Materials, 40, 982-1000, 2008.
A. Siddiq, E. Ghassemieh, Theoretical and FE Analysis of Ultrasonic Welding of Aluminium Alloy 3003, ASME: Journal of Manufacturing Science and Engineering, 131, 041007-1-11, 2009.
Z. Zhu, B. P. Wynne, E. Ghassemieh, A. Siddiq, Microstructural Analysis of Ultrasonic Welded AA6061 by Electron Backscattered Diffraction, Rare Metal Materials and Engineering, 38, 147-151, 2009.
A. Siddiq, E. Ghassemieh, Fibre Embedding in Aluminium Alloy 3003 using Ultrasonic Consolidation Process – Thermomechanical Analyses, International Journal Advanced Manufacturing Technology, 54, 997-1009, 2011.
A. Siddiq, E. Ghassemieh, Computational Modelling of Fibre Embedding in Aluminium Alloy (AA6061) during Ultrasonic Consolidation Process, International Journal of Materials Engineering Innovation, 2, 182-202, 2011.
A. Siddiq, T. El Sayed, Acoustic Softening in Metals during Ultrasonic Assisted Deformation via CP-FEM, Materials Letters, 65, 356-359, 2011.
A. Siddiq, T. El Sayed, A Thermomechanical Crystal Plasticity based Constitutive Model for Ultrasonic Consolidation Process, Computational Materials Science, 51, 241-251, 2012.
A. Kvits, A. Siddiq, Computational modelling of metal 3D printing, UoA Report 2018, 1-49, 2018.