SonicGEN™: Revolutionising Ultrasonic-Assisted Manufacturing
SonicGEN™ powers Ultrasonic-Assisted Advanced Manufacturing (UAAM), combining traditional manufacturing with ultrasonic vibrations to enhance quality, strength, and durability.
Key Benefits :
-
Stronger Material Bonding
-
Enhanced Toughness and Tensile Strength
-
Improved Microstructure Uniformity
Industries Leveraging UAAM:
-
Aerospace Manufacturing
-
Medical Device Production
-
Consumer Goods Manufacturing
UAAM enables the creation of lightweight, complex, and high-performance components, transforming the future of advanced manufacturing.
SonicGEN™: Innovative Ultrasonic Technology for Modern Industries.
Use Case:
Enhancing Laser Additive Manufacturing (AM) with SonicGEN™
Background
Additive Manufacturing (AM) technologies are extensively used for metal fabrication in industries like aerospace, marine, and automotive. However, conventional AM processes face challenges such as:
-
Porosity and cavity formation
-
Cracking and residual stress
-
Large heat-affected zones
-
Uncertain microstructures
These issues compromise the quality and mechanical properties of the fabricated components.
Solution: SonicGEN™ Integration
SonicGEN™ introduces a high-pressure ultrasonic field during the AM process, agitating the melt pool to refine the material's properties. This innovation delivers:
-
Grain Size Reduction: ~10 µm (compared to 40 µm without SonicGEN™)
-
Defect Reduction: 80% fewer imperfections
Impact
With SonicGEN™, manufacturers can achieve stronger, more reliable components with improved quality and consistency, revolutionizing the potential of Laser AM technology.
Core Principle of SonicGEN™ Technology
SonicGEN™ leverages ultrasonic waves (>20 kHz) to enhance material properties during the liquid phase. These sound waves induce alternating high-pressure (compression) and low-pressure (rarefaction) cycles, generating microscopic vacuum bubbles in the liquid. The collapse of these bubbles (cavitation) produces intense local temperatures, leading to:
-
Microstructure Refinement
-
Improved Surface Quality
-
Enhanced Adhesion
-
Defect Reduction/Elimination
This innovative process ensures superior material performance and sets a new standard in advanced manufacturing.
Schematics of the experimental setup
(a-c) without and (d-f) with processing using SonicGEN™
