US 12,257,652 B2
Method for using soluble sacrificial materials in ultrasonic additive manufacturing
Justin Wenning, Columbus, OH (US)
Filed by FABRISONIC LLC, Columbus, OH (US)
Filed on Feb. 9, 2022, as Appl. No. 17/667,943.
Application 17/667,943 is a continuation of application No. 16/369,019, filed on Mar. 29, 2019, abandoned.
Prior Publication US 2022/0168852 A1, Jun. 2, 2022
Int. Cl. B23K 35/36 (2006.01); B22F 1/10 (2022.01); B22F 3/105 (2006.01); B23K 20/10 (2006.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); C08K 3/16 (2006.01); C08L 29/04 (2006.01)
CPC B23K 35/3613 (2013.01) [B22F 1/10 (2022.01); B22F 3/105 (2013.01); B23K 20/10 (2013.01); B23K 35/3603 (2013.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); C08K 3/16 (2013.01); C08L 29/04 (2013.01)] 15 Claims
 
1. A method for ultrasonic additive manufacturing, comprising:
(a) using ultrasonic additive manufacturing to build a solid metal object through ultrasonically welding successive layers of thin metal foil into a three-dimensional shape;
(b) machining internal features into the solid metal object, wherein the internal features include voids, chambers, cavities, channels, or conduits;
(c) 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;
(d) curing the sacrificial support material at a predetermined temperature for a predetermined period of time within the internal features;
(e) using ultrasonic additive manufacturing to deposit additional successive layers of metal on top of the sacrificial support material and solid metal object to complete the solid metal object;
(f) introducing a solution containing water into the internal features to dissolve and remove the sacrificial support material therefrom; and
(g) machining channels or other features into the sacrificial support material for facilitating extraction thereof from the completed solid metal object.