Depositing heat-treated aluminum using ultrasonic consolidation

Abstract

A system, method, and articles are disclosed with respect to depositing aluminum or alloys thereof, utilizing ultrasonic object consolidation. The method aspect of the invention comprises the steps of heat-treating an aluminum-based feedstock and ultrasonically consolidating the feedstock to a substrate to produce a part or a repair of a part, as might be required in an aerospace or aircraft structure. The feedstock may be solution heat-treated. This would include situations wherein the feedstock is solution heat treated off-line and maintained under controlled temperature conditions to prevent precipitation of solutes prior to the ultrasonic consolidation. Alternatively, the feedstock may be heat-treated on-line by passing it through a temperature- and/or atmosphere-controlled chamber prior to ultrasonic consolidation. The feedstock may be supported to minimize slumping due to creep. The feedstock may be T4, or may be aged, to T6, for example. The feedstock may be allowed to age naturally at room temperature, or a heat source may be used to artificially age the consolidated feedstock. The substrate may be aged or unaged. The source of the aluminum-based feedstock is in the form of tapes, sheets, wires, or droplets.

1 . A method depositing aluminum or an alloy thereof, comprising the steps of: 
 heat treating an aluminum-based feedstock; and    ultrasonically consolidating the feedstack to a substrate.    
   
   
       2 . The method of  claim 1 , wherein the feedstock is solution heat treated.  
   
   
       3 . The method of  claim 1 , wherein the feedstock is solution heat treated off line and maintained under controlled temperature conditions to prevent precipitation of solutes prior to the ultrasonic consolidation.  
   
   
       4 . The method of  claim 1 , wherein the feedstock is heat-treated on-line by passing it through a temperature- and/or atmosphere-controlled chamber prior to ultrasonic consolidation.  
   
   
       5 . The method of  claim 1 , wherein the feedstock is supported to minimize slumping due to creep.  
   
   
       6 . The method of  claim 1 , wherein the feedstock is T4.  
   
   
       7 . The method of  claim 1 , wherein the feedstock is aged.  
   
   
       8 . The method of  claim 1 , wherein the feedstock is aged to T6.  
   
   
       9 . The method of  claim 1 , wherein the feedstock is allowed to age naturally at room temperature.  
   
   
       10 . The method of  claim 1 , wherein a heat source is used to artificially age the consolidated feedstock.  
   
   
       11 . The method of  claim 1 , wherein the substrate is aged or unaged.  
   
   
       12 . The method of  claim 1 , wherein the substrate forms parts of an aerospace or aircraft structure.  
   
   
       13 . A product constructed using the process of  claim 12 .  
   
   
       14 . A system for depositing aluminum or an alloy thereof, comprising: 
 a source of aluminum-based feedstock;    a subsystem for heat-treating the feedstock; and    an ultrasonic consolidation subsystem for bonding the heat-treated feedstock to a substrate.    
   
   
       15 . The system of  claim 14 , wherein the feedstock is solution heat treated.  
   
   
       16 . The system of  claim 14 , further including a temperature- and/or atmosphere-controlled chamber through which the feedstock passes prior to ultrasonic consolidation.  
   
   
       17 . The system of  claim 14 , further including a feedstock support to minimize slumping due to creep.  
   
   
       18 . The system of  claim 14 , further including a heat source to artificially age the consolidated feedstock.  
   
   
       19 . The system of  claim 14 , wherein the subsystem for heat-treating the feedstock performs a solution heat-treatment process.  
   
   
       20 . The system of  claim 14 , wherein the source of aluminum-based feedstock is in the form of tapes, sheets, wires, or droplets.