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  1. Free, publicly-accessible full text available July 1, 2024
  2. Abstract Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process capable of producing near-net-shape metal parts. Recent studies have shown the promise of UAM welding of steels. However, the effect of weld parameters on the weld quality of UAM steel is unclear. A design of experiments study based on a Taguchi L16 design array was conducted to investigate the influence of parameters including baseplate temperature, amplitude, welding speed, and normal force on the interfacial temperature and shear strength of UAM welding of carbon steel 4130. Analysis of variance (ANOVA) and main effects analyses were performed to determine the effect of each parameter. A Pearson correlation test was conducted to find the relationship between interfacial temperature and shear strength. These analyses indicate that a maximum shear strength of 392.8 MPa can be achieved by using a baseplate temperature of 400°F (204.4°C), amplitude of 31.5 μm, welding speed of 40 in/min (16.93 mm/s), and normal force of 6000 N. The Pearson correlation coefficient is calculated as 0.227, which indicates no significant correlation between interfacial temperature and shear strength over the range tested. 
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  3. Demand is expected to accelerate for autonomous air vehicles that transport people and goods, making wind sensors on these vehicles and in the air space where they operate critical to ensure safe control of many simultaneous take-offs and landings. Conventional anemometers such as pitot tubes as well as rotating, heated-element, acoustic, and drag technologies have drawbacks for small and micro-aerial vehicles including high power consumption, high aerodynamic drag, complex signal processing, and high cost. This paper presents an airfoil-shaped anemometer that provides low drag while integrating sensors for measuring wind speed and direction on tethered kites, balloons, and drones. Wind speed is measured by an integrated dual-layer capacitive pressure sensor with a polyvinylidene fluoride (PVDF) diaphragm while wind direction is measured by a 3D digital magnetometer that senses the orientation of the airfoil relative to the earth’s magnetic field. A model is presented for a dual-layer capacitive sensor and validated through quasistatic pressure chamber testing. The capacitive sensor as well as a commercial digital magnetometer are integrated into a NACA 2412 profile airfoil and tested in a laboratory-scale wind tunnel. The capacitive sensor provides a sensitivity of 1.84 fF m 2 s −2 and the airfoil exhibits a unique stable angle-of-attack to within ±2° as measured by the magnetometer. 
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  4. Abstract Soft robotic grippers can gently grasp and maneuver objects. However, they are difficult to model and control due to their highly deformable fingers and complex integration with robotic systems. This paper investigates the design requirements as well as the grasping capabilities and performance of a soft gripper system based on fluidic prestressed composite (FPC) fingers. An analytical model is constructed as follows: each finger is modeled using the chained composite model (CCM); strain energy and work done by pressure and loads are computed using polynomials with unknown coefficients; net energy is minimized using the Rayleigh–Ritz method to calculate the deflected equilibrium shapes of the finger as a function of pressure and loads; and coordinate transformation and gripper geometries are combined to analyze the grasping performance. The effects of prestrain, integration angle, and finger overlap on the grasping performance are examined through a parametric study. We also analyze gripping performance for cuboidal and spherical objects and show how the grasping force can be controlled by varying fluidic pressure. The quasi-static responses of fabricated actuators are measured under pressures and loads. It is shown that the actuators’ modeled responses agree with the experimental results. This work provides a framework for the theoretical analysis of soft robotic grippers and the methods presented can be extended to model grippers with different types of actuation. 
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  5. Purpose Ultrasonic additive manufacturing (UAM) is a solid-state joining technology used for three-dimensional printing of metal foilstock. The electrical power input to the ultrasonic welder is a key driver of part quality in UAM, but under the same process parameters, it can vary widely for different build geometries and material combinations because of mechanical compliance in the system. This study aims to model the relationship between UAM weld power and system compliance considering the workpiece (geometry and materials) and the fixture on which the build is fabricated. Design/methodology/approach Linear elastic finite element modeling and experimental modal analysis are used to characterize the system’s mechanical compliance, and linear system dynamics theory is used to understand the relationship between weld power and compliance. In-situ measurements of the weld power are presented for various build stiffnesses to compare model predictions with experiments. Findings Weld power in UAM is found to be largely determined by the mechanical compliance of the build and insensitive to foil material strength. Originality/value This is the first research paper to develop a predictive model relating UAM weld power and the mechanical compliance of the build over a range of foil combinations. This model is used to develop a tool to determine the process settings required to achieve a consistent weld power in builds with different stiffnesses. 
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  8. Meyendorf, Norbert G. ; Farhangdoust, Saman (Ed.)
    Metal-matrix composites with active components have been investigated as a way to functionalize metals. As opposed to surface-mounted approaches, smart materials embedded in metals can be effectively shielded against the environment while providing in-situ sensing, health monitoring, actuation, or energy harvesting functions. Typical manufacturing approaches can be problematic, however, in that they may physically damage the smart material or degrade its electromechanical properties. For instance, non-resin-based embedment procedures such as powder metallurgy involve isostatic compression and diffusion bonding, leading to high process temperatures and breakdown of the electromechanical properties of the active component to be embedded. This paper presents the development and characterization of an aluminum-matrix composite embedded with piezoelectric polyvinylidene fluoride (PVDF) sensors using ultrasonic additive manufacturing (UAM). UAM incorporates the principles of solid-state, ultrasonic metal welding and subtractive processes to fabricate metal-matrices with seamlessly embedded smart materials and without thermal loading. As implemented in this study, the UAM process uses as-received, commercial Al 6061 tape foilstock and TE Connectivity PVDF film. In order to increase the mechanical coupling between the sensor and the metal-matrix without the aid of adhesives, the PVDF sensor is embedded with an empirically optimized pre-compression defined by the tape foils welded above the sensor. The specimen is characterized by tensile (d31 mode), bending (d31 mode), and compression tests (d33 mode) to evaluate its functional performance. Within the investigated load range, the specimen exhibits open-circuit sensitivities of 4.6 mV/N under uniaxial tension and 9.7 mV/N under compressive impulse tests with better than 95% linearity and frequency bandwidth of several kilohertz. The technology presented in this study could be applied for load and tactile sensing, impact detection and localization, thermal measurements, energy harvesting, and non-destructive testing applications. 
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