Abstract: A method of ultrasonic additive manufacturing comprising using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape; machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits; depositing a sacrificial support material in the internal features, wherein the sacrificial support material includes at least one water-soluble solid, and at least one water-soluble binding agent; curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features; using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial material and solid metal object to complete the solid metal object; and introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefro

Abstract: An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.

Abstract: An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.

Abstract: A sacrificial material for use in ultrasonic additive manufacturing processes that includes at least one water-soluble solid; and at least one water-soluble binding agent, wherein the at least one water-soluble solid is partially dissolved or suspended in the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.

Abstract: An ultrasonic welding apparatus that includes a full-wave sonotrode that further includes a first horn, a first nodal region, a welding surface, a second nodal region, and a second horn; first and second bearing assemblies that support the sonotrode at the first and second nodal regions respectively, wherein each bearing assembly further includes a first bearing housing portion; a first low friction bearing disposed within the first bearing housing portion; a second bearing housing portion connected to the first bearing housing portion; and a second low friction bearing disposed within the second bearing housing portion; a first centering apparatus that exerts laterally-acting force on the horn of the full-wave sonotrode; and a second centering apparatus that exerts laterally-acting force on the second horn of the full-wave sonotrode.