Laminated interface characterization and Cohesive Zone Modeling (CZM) of fracture for Ultrasonic Additive Manufacturing (UAM) structures

Finite element-based characterization of interface strength in Ultrasonic Additive Manufacturing (UAM) is crucial for accurately simulating failure behavior in UAM components and reducing experimental requirements. This study introduces a testing methodology using specially designed dovetail-shaped UAM samples to characterize UAM interfaces for finite element modeling. These samples enable loading in three distinct configurations, generating varied stress distributions at the weld interface to induce failure. A fracture mechanics approach, utilizing the cohesive zone model (CZM), is applied in finite element method (FEM) simulations to characterize the interface behavior. Tests in the three configurations are simulated in FEM and the CZM parameters are calibrated against the experimental data to accurately characterize the weld interface. These calibrated parameters are suitable for broader failure simulations of UAM structures. Model validation was achieved by accurately predicting experimental fracture behavior for a different loading configuration, with an error of only 10.1%. • Finite element methodology for UAM interface fracture characterization • Dovetail UAM samples tested under distinct loading configurations • Cohesive zone model formulated and calibrated from experimental data • FEM–CZM model validated for arbitrary interface loading conditions