Study on Ultrasonically Actuated Molding: Evaluating an Alternative Manufacturing Method for Enhanced Lightweight Structures

Abstract

This study explores ultrasonic treatment (UT) as an alternative to conventional casting methods for lightweight, high-strength materials, with a focus on aerospace applications. The approach in this study integrates computational modeling and experimental validation to design and optimize a two-piece mold system. Ultrasonic energy was applied during the solidification of tin, selected for its low melting point, to evaluate its effects on material properties. The process exploited advanced modeling techniques in COMSOL Multiphysics, addressing key factors such as acoustic pressure and cavitation dynamics. The experimental results reveal significant improvements in mechanical properties, including an increase in tensile strength 13% and considerable improvements in ductility and yield strength compared to traditional casting methods. This work demonstrates the potential of UT to improve casting quality and mechanical properties, paving the way for its application to more complex or different variants of aerospace materials through compliance with a simulation model. Future research will focus on scaling the method for more complex alloys and industrial environments. First and foremost, the authors would like to express their thanks to everyone who helped make this study possible. The authors would like to express their special thanks to Asst. Prof. Yiğit Taşçıoğlu and Assoc. Prof. Arif Sanlı Ergün for their guidance and direction in this study. The authors would also like to thank technician Kamil Arslan for his assistance with the laboratory work. In addition, the authors would like to thank Eren Can Ergül and Fırat Memu for their dedication and assistance in this project, which was very much appreciated. © 2025, American Institute of Aeronautics and Astronautics Inc, AIAA. All rights reserved.