New-emerging approach for fabrication of near net shape aluminum matrix composites/nanocomposites: Ultrasonic additive manufacturing

Recently, high-performance lightweight materials with outstanding mechanical properties have opened up their way to some sophisticated industrial applications. As one of these systems, aluminum matrix composites/nanocomposites (AMCs) offer an outstanding combination of relative density, hardness, wear resistance, and mechanical strength. Until now, several additive manufacturing methods have been developed for fabrication of 3D metallic components among them, selective laser melting (SLM), electron beam melting (EBM), laser metal deposition (LMD), Wire+Arc additive manufacturing (WAAM), and ultrasonic additive manufacturing (UAM) are of prime significance. Unlike other methods, in ultrasonic additive manufacturing, the ultrasonic waves are used instead of applying the sintering process. This technique is well-known for its ability to produce 3D components by repeating the alternative welding and machining procedures at low temperatures. This is why it can overcome the technological issues arisen from the high-temperature sintering. The present review strives to provide an inclusive introduction to the principles of ultrasonic additive manufacturing method and recent advances in ultrasonic additive manufacturing of aluminum matrix composites/nanocomposites. Also, the challenges of this new emerging technique, i.e. its dependence to the applied weld power, is addressed in the paper. The authors attempt to give some perspectives to the researchers for further investigations in this new-emerging field.