Honda Motor Co., Ltd.
Continuous ultrasonic additive manufacturing

Abstract:

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.