Soluble sacrificial materials for use in ultrasonic additive manufacturing

Abstract

A sacrificial material for use in ultrasonic additive manufacturing processes that includes at least one water-soluble solid; and at least one water-soluble binding agent, wherein the at least one water-soluble solid is partially dissolved or suspended in the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.

What is claimed: 
     
         1 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:
 (a) at least one water-soluble solid; and   (b) at least one water-soluble binding agent,   (c) wherein the at least one water-soluble solid is mixed with the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.   
     
     
         2 . The sacrificial material of  claim 1 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one powdered metal, sand, or combinations thereof. 
     
     
         3 . The sacrificial material of  claim 1 , wherein ratio of the at least one water-soluble solid to the at least one water-soluble binding agent is five parts water-soluble solid to one part water-soluble binding agent, by volume. 
     
     
         4 . The sacrificial material of  claim 1 , wherein the water-soluble solid is a sodium salt, a potassium salt, an ammonium salt, or combinations thereof. 
     
     
         5 . The sacrificial material of  claim 1 , wherein the water-soluble binding agent is a synthetic polymer. 
     
     
         6 . The sacrificial material of  claim 1 , wherein the water-soluble binding agent is polyvinyl alcohol, polyvinyl acetate, or a combination thereof. 
     
     
         7 . The sacrificial material of  claim 1 , wherein the predetermined temperature is within the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours. 
     
     
         8 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:
 (a) a water-soluble solid; and   (b) a water-soluble binding agent, wherein the water-soluble binding agent includes a synthetic polymer, wherein the synthetic polymer is polyvinyl alcohol or polyvinyl acetate, and   (c) wherein the water-soluble solid is mixed with the water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.   
     
     
         9 . The sacrificial material of  claim 8 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one powdered metal, sand, or combinations thereof. 
     
     
         10 . The sacrificial material of  claim 8 , wherein ratio of the water-soluble solid to the water-soluble binding agent is five parts water-soluble solid to one part water-soluble binding agent, by volume. 
     
     
         11 . The sacrificial material of  claim 8 , wherein the water-soluble solid is a sodium salt, a potassium salt, an ammonium salt, or combinations thereof. 
     
     
         12 . The sacrificial material of  claim 8 , wherein the predetermined temperature is in the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours. 
     
     
         13 . A sacrificial material for use in ultrasonic additive manufacturing, comprising:
 (a) a solid, wherein the solid is sodium chloride; and   (b) a binder, wherein the binder is polyvinyl alcohol, and   (c) wherein the solid is mixed with the binder and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.   
     
     
         14 . The sacrificial material of  claim 13 , further comprising a stiffening component, wherein the stiffening component includes fiber glass, at least one metal powder, sand, or combinations thereof. 
     
     
         15 . The sacrificial material of  claim 13 , wherein ratio of the solid to the binder is five parts solid to one part binder, by volume. 
     
     
         16 . The sacrificial material of  claim 13 , wherein the solid is water soluble. 
     
     
         17 . The sacrificial material of  claim 13 , wherein the binder is water soluble. 
     
     
         18 . The sacrificial material of  claim 13 , wherein the predetermined temperature is in the range of 23° C. to 200° C., and wherein the predetermined period of time is within the range of fifteen minutes to twenty-four hours.