Ultrasonic vibration micro-jet ejection for metal additive manufacture

In comparison to laser additive manufacturing, metal droplet deposition technology presents substantial cost benefits by obviating the necessity for costly metal powders and high-power lasers. Nonetheless, prevalent metal droplet deposition methodologies often grapple with challenges such as intricate drive architectures, substantial droplet volumes, and diminished jetting frequencies. This paper proposes an ultrasonic vibration micro-jet ejection technique and constructs a prototype for metal additive manufacturing. Utilizing ultrasonic vibration of a tool rod, the technique generates a high-frequency acoustic pressure field within the crucible, which facilitates the ejection of molten metal from the nozzle. The study explores two operational modes: continuous jet and on-demand jet. It was determined that the tool rod's amplitude must exceed a certain threshold to initiate metal ejection. As the amplitude further increases, the droplet jetting behavior transitions from uniform to non-uniform ejection states. To enhance formability quality, the study examined the influence of various process parameters on single-pass and three-dimensional forming. The examination of jetted parts revealed that both uniform and non-uniform jets provide satisfactory formability and mechanical performance. This research presents a new direction for achieving efficient metal droplet jetting forming.