An Energy Dissipative Constitutive Model for Multi-Surface Interfaces at Weld Defect Sites in Ultrasonic Consolidation

A new finite element based constitutive model has been developed for quantification of energy dissipation due to friction and plastic deformation at the mating interface of two surfaces during the Ultrasonic Consolidation process. This work will include bridging the mesoscopic response of a dislocation density based crystal plasticity finite element framework at inter and intra-granular scales and a point at the macroscopic scale. This response will be used to develop an energy dissipative constitutive model for multi-surface interfaces at the macroscopic scale. The constitutive model will be used for quantification of energy consumed at lack of fusion and trapped oxide defects present in the build and the amount of energy input required to compensate for it. This numerical procedure will help in real time optimization of process parameters and closed loop control.