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Disruptive Technologies in Forming and Joining Glenn S. Daehn, Daehn.1@osu.edu

Impulse Manufacturing Lab Center for Design and Manuf. Excellence iml.osu.edu cdme.osu.edu

And other Collaborators from OSU and LIFT

Detroit, 20 February 2019

Disrup'oniscoming

•  Why

•  What

•  How– MetamorphicManufacturing–  ImpulseManufacturing

•  Who

Why?

Changeisinevitableduetoglobalforces:Climatechange

Howweusevehicles.

Carbonwilldrivedecisions,likely,soon

Gore’sInconvenient Truth

released - 2006Presenterborn

280 ppm (last ~500 years) far pre-history ~200 ppm in ice agesLast 1000 years

Energyflows(Sankeydiagram)

2/3 energy is used in production and transportation!

Megatrendsinauto

•  Moresharing(Uber,LyJ,scooters,etc.)

•  Moreautotomy(sharing)

•  Fewercarsperfamily

•  Worldwidemanufacturingovercapacity

•  Electrifica'on

•  Lessownership(isconsumerismdead?)

What?

AutomobilesmaylookmorelieaircraJ.Drivenbyu'lity,notstyle

Ultra-durable,basedonshearing-layerconcept.

Whatdothetrendsmeanformanufacturers?

•  Farfewer,butfarbeOerautos.– Light– Autonomous– Electric– Durable

•  Longerlivedcars(mostincorporatefleets)

•  Stylingnearlyirrelevant,comfortwillbevalued.– Exteriorstylingathinganymore?Whowashesarental?

Wheredoesthisgo?

•  Carsmightlooklike737’s/787’s•  Operatefordecades;upgradedandrefurbishedasrequired

–  BaOeries–  Opera'ngSystem–  Centralprocessor–  SensorSuite–  Interior–  Tires–  Propulsionsystem

Minimalbutfunc'onal;Edison2,VLC(verylightcar)Winner of 2010 $5M Progressive X-Prize for 100 MPGe mainstream vehicle. Demonstrating: Safety, Manufacturability, features and seating for 4. Frame and skin design similar to aircraft.

Energyabsorbingfrontend

CastorforgedBulkheads&frame

HighStrengthSteelCabin

Rolling chassis can have varied powertrains, sensors, interiors on standard connections

Whatmightthefuturelooklike?

•  Smallerpartcount

•  High-quality,high-strength,lightweightcomponents.

•  High-strengthmul'-materialjoints

•  Agile,digital,on-demandmanufacturing(goalofaddi've)

How?

Processeshigherqualityandagility.MetamorphicManufacturing

ImpulseManufacturingandJoining.

MetamorphicManufacturing

Shapingassuredcomponents,ondemand.

Project in collaboration with:LIFT Manufacturing USA instituteTMSAlan Taub (U of Michigan)

DigitalManufacturing:Hope&HypeFirst Wave – CNC Removal USAF Funding at (MIT) starting in 1949.

Second Wave – AM Additive NSF, etc., early 1980’s

ThirdWave:Metamorphic

Robot

ICME-Computer

Sensors-Computer-Wires

Work-Horseshoe

Heat-Lazers

Machine

Sensors

ToolInterchangableheads

2

Robotwork holdingtool change

SensorstemperatureshapemicrostructureWorkpiece

Interchangeable tools

Sensorstemperatureshapemicrostructure

Powered Toolservo-presspower hammer, etc.

ComputerICMEshape à strainprocess sequenceAI & machine learning

Thermallasersinductioninfraredflameor cool/quench

Proof:Plas=cineandMetal

Robot

TeamHoneyBadger,ofOhioStateUniversity.AlexKoenig,BhuviNirudhoddiandBrianThurstonSee:Robo'cBlacksmithing.comfordetails.

LIFTPrize–$25kofferedforasingleprogrammablesystemthatcanshape2of3targetparts.

Technical:What

Germananonymous,circa1606

High-ValueComponent

SimulationandICME

Machine

Heatingand

CoolingSensors

Position

Track with time: •  Temperature •  Strain tensor •  Stress tensor Predict: •  Microstructure •  Damage •  Anisotropy •  Etc…

MetamorphicTMSreportreleaseMarch11,2019

ImpulseManufacturing

Largeforce,shortdura'onprocessing

AcknowledgementstoDr.AnupamVivekandmyteamatOSU’sImpulseManufacturingLab

hOp://iml.osu.edu

How:ImpulseManufacturing?Explosives Direct Impact Impact Presses

Laser Impulse

Capacitive Discharge Elecrohydraulic

Electromagnetic Vaporizing Foil

Fromstresstech.com

Water Confinement

OpticalPulse

t

Primary Ionization

Parasitic Ionization

ShockFronts

100 kAFlyer

Target

PDV Probe

Standoff

Whyimpulseandhighspeed?Enhanced Formability Conformal Joining Collision Welding

Embossing Cutting Precision Shape Control

Flanging/Hemming Shock Hardening Light & Agile Equipment

400µm%

Cu#

#

Ti#

500#µm#

Aluminum'foil'

Die''

Work'piece'

Clamping'force'

Die''

Fixture''

Fixture''

Whatistheidealdissimilarmetalinterface?

Transition metals share electrons…

Atomically clean, flat surfaces would bond.

Can conventional methods do this?

What kind of process can?

Impactwelding

•  Je'ngcleanssurfaces

•  Ultrahighpressuresforatomiccontact.

•  Largeplas'cstrains

•  Adiaba'chea'ng:deforma'on,fric'on,gas

•  Localheterogeneity

•  Veryrapidcooling

•  Reflectedstresswaves(top) mechanism of Bahrani, Black and Corssland, Proc. Roy. Soc., (1967).

Solid-StateWelding(CivilizedExplosiveWelding)•  ProcessàStructureàProper'esofanewweldingprocess

– Solid-State– Noheat– Nodistor'on– Noheataffectedzones– Parentmetalstrength–  Joinsstrongalloys–  Joinsdissimilaralloys– <20%energyoffusionwelding– SimpleEquipment– Singlesidedpossible

steel

Aluminum

ProcessingàStructureàProper'es

wavymelt

voids

VW

(5748m/s)(8◦) VW

(1893m/s)(24◦) VW

(937m/s)(28◦)

Vivek,Liu,HansenandDaehn,J.MaterProc.2014

wavy

melt voids

SmoothedPar'cleHydrocodeSimula'on800m/s,20°impactTionCu

Nassiri, Appl Phys Let (2017)– LS DYNA SPH

Cu

Ti

Cu

Ti

Advanced/DissimilarMetalWelding

Cu- Zr BMG Cu-17F W alloy AA6061-AZ91D CP Ti-1018 steel

AA6061-SS304 AA6061-Cu Ti 6242-Inconel 718 Cu-CP Ti

•  Solid-State•  No heat•  No distortion •  No heat affected zones•  Parent metal strength•  Joins strong alloys•  Joins dissimilar alloys•  <20% energy of fusion•  Simple Equipment

AA5052 / DP980 AA5052 / 22MnB5 AA6111-T4 / DP980 AA6111-T4 / 22MnB5

ManualAl-FeFlangeWeld

CommercializingtheVFAMethod

20 impact welds~1.5 m long

• Automated foil feed• Automated part feed• Weld training • Cycle time: <3 sec•.Noise: <85 decibels

VFAWResearch&Prototypingsystem

•  Takingtechnology“outsidethelab”

•  Betasystemsbeingsetupatweldtrainingschoolandprototypeshops

VFAWHowthick?

A 1100

1018 Steel

A 3003

1018 Steel

A 50526mm

10 kJ discharge energy,~ 250 m/s impact speed

6mm

Who?

Fortunefavorsthebold.EmbracechangeHavepurpose.

Differentisprofitable!Market Capitalization: 2010 to now

Ford Tesla

Plot via Wolfram Alpha

FordGM

Summary:Disrup'oniscoming

•  Why

•  What(onevision)

•  How– MetamorphicManufacturing–  ImpulseManufacturing

•  Who

•  BeBold

Acknowledgements

Details: iml.osu.edu