A method for making a cold plate includes the steps of positioning a finstock structure in a cavity of a substrate; and applying a cover to the finstock structure and substrate, wherein the applying step comprises ultrasonically additive manufacturing the cover to the substrate and the finstock structure, whereby the cover joins with the substrate and the finstock structure. The resulting cold plate assembly includes a substrate having a cavity, a finstock structure within the cavity, and a cover closing the finstock structure within the cavity, the cover being integrally joined to the substrate and to the finstock structure.

Methods of ultrasound assisted 3D printing and welding involve the use of an ultrasonic sonotrode placed in on top of the solidified layer in the vicinity of a melt pool. The sonotrode, pressed against the solidified materials at the edge of the melt pool, is synchronized with the heat source such that it travels side-by-side with the melt pool to transmit ultrasonic vibrations to the solidifying melt pool, reducing hot tearing and porosity formation, and to consolidate the solidified materials under the sonotrode. The methods of the present invention are capable of making a large variety of commercially important alloys 3D printable and weldable.

The present invention relates to a welding apparatus including an electrode assembly configured such that a plurality of positive electrodes and a plurality of negative electrodes are stacked in the state in which separators are interposed therebetween, guides configured to reduce tensile force of positive electrode tabs and negative electrode tabs protruding from the electrode assembly, an anvil configured to allow the electrode tabs to be disposed thereon, and a horn configured to apply ultrasonic waves to the electrode tabs disposed on the anvil, a welding method using the same, and an electrode assembly manufactured by the welding method.

A system includes a first horn, a first ultrasonic transducer, a second horn, a second ultrasonic transducer, a memory, and a controller. The first horn includes a first part-interfacing surface. The second horn includes a second part-interfacing surface and is positioned relative to the first horn such that a part to be welded can be positioned between the first and second part-interface surfaces. The controller is configured to cause a first ultrasonic energy to be applied through the first horn via the first transducer to cause the first part-interfacing surface to vibrate, cause the first horn to move in a first direction at a first time, cause a second ultrasonic energy to be applied through the second horn via the second transducer to cause the second part-interfacing surface to vibrate, and cause the second horn to move in a second direction at the first time.

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.

The present invention relates to a method for intermittent ultrasonic processing of a length of material, wherein a length of material is moved through between a sonotrode and a counter-tool and the length of material is processed intermittently. In order to specify a method for intermittent ultrasonic processing of a length of material by which the disadvantages of the prior art can be avoided or at least reduced, according to the invention it is suggested that in a processing interval the sonotrode is stimulated by an ultrasonic oscillation with an oscillation amplitude A and in a movement interval the sonotrode is stimulated with an oscillation amplitude B, wherein B<A and during the processing interval and during the movement interval the length of material touches both the sonotrode and also the counter-tool.

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.

A method of forming a cooling structure for a heat-dissipating surface includes arranging a heat spreader layer adjacent the heat-dissipating surface, bonding a coldplate directly to the heat spreader layer opposite the heat-dissipating surface, and forming an intermetallic bond between the heat spreader layer and the coldplate. The coldplate is bonded to the heat spreader layer using ultrasonic additive manufacturing.

The invention belongs to the field of additive manufacturing of amorphous alloy, and discloses a laser 3D printing forming system of amorphous alloy foil and a forming method thereof. The unnecessary material of the amorphous alloy foil is cut by a first laser and then the remaining portion is selectively scanned and heated by a second laser so that the amorphous alloy is heated to be in a superplastic state in the supercooled liquid region. Then, the amorphous alloy foil is rolled by a preheated roller in combination with the ultrasonic vibration to achieve interatomic bonding between layers of the amorphous alloy foil, and the amorphous alloy foil is then rapidly cooled, so that an amorphous alloy part with a large size, a complicated shape and a porous structure is formed. The invention has overcome the limitation of the size and shape of the amorphous alloy prepared by the traditional amorphous alloy preparation methods, and uses amorphous alloy foil as a raw material, which has lower cost than the traditional 3D printing amorphous powder. In addition, a roller is used to roll the ultra-thin amorphous alloy foil such that the prepared amorphous alloy part has a more compact internal structure.

The present disclosure relates to a welding device and a processing apparatus for a secondary battery current collector. The welding device includes: a welding head; and an anvil block. A welding station is disposed between the welding head and the anvil block. The welding device is configured to weld a foil to a portion of a composite current collector at the welding station. According to this solution, the foil can be used as a tab of the composite current collector by using the foil to connect with the composite current collector so as to output the current in the battery cell.