Ross James Friel

Halmstad University · ITE- School of Information Technology

Additive Manufacturing is transforming how researchers and industrialists look to design and manufacture chemical devices to meet their specific needs. In this work, we report the first example of a flow reactor formed via the solid-state metal sheet lamination technique, Ultrasonic Additive Manufacturing (UAM), with directly integrated catalytic s...

Some of the most fundamental chemical building blocks of life on Earth are the metal elements. X-ray absorption spectroscopy (XAS) is an element-specific technique that can analyse the local atomic and electronic structure of, for example, the active sites in catalysts and energy materials and allow the metal sites in biological samples to be ident...

Additive Manufacturing is transforming how researchers and industrialists look to design and manufacture chemical devices to meet their specific needs. In this work, we report the first example of a flow reactor formed via the solid-state metal sheet lamination technique, Ultrasonic Additive Manufacturing (UAM), and featuring directly integrated ca...

Additive Manufacturing (AM); commonly known as 3D printing, is a family of novel and advanced manufacturing techniques that operate in a layer-by-layer additive manner and, by using a vast material palette, can deliver parts in an autonomous fashion directly from computer data without the need for additional tooling and with part complexities beyon...

Ultrasonic Additive Manufacturing (UAM) is a solid-state metal additive manufacturing process that uses periodic CNC machining to create internal and external geometries, layer-by-layer. The solid-state nature of the bonding process (ultrasonic metal welding) allows UAM to directly bond metal materials with significantly different thermal, hardness...

BioMAX is the first macromolecular crystallography beamline at the MAX IV Laboratory 3 GeV storage ring, which is the first operational multi-bend achromat storage ring. Due to the low-emittance storage ring, BioMAX has a parallel, high-intensity X-ray beam, even when focused down to 20 µm × 5 µm using the bendable focusing mirrors. The beam is tun...

Over the last decade, serial crystallography, a method to collect complete diffraction datasets from a large number of microcrystals delivered and exposed to an X-ray beam in random orientations at room temperature, has been successfully implemented at X-ray free-electron lasers and synchrotron radiation facility beamlines. This development relies...

Introduction Microfluidic reactionware allows small volumes of reagents to be utilized for highly controlled flow chemistry applications. By integrating these microreactors with onboard analytical systems, the devices change from passive ones to active ones, increasing their functionality and usefulness. A pressing application for these active micr...

Background: The purpose of this study was to determine if 3D printed lenses with wavelength specific anti-reflective (AR) surface structures would improve beam intensity and thus radar efficiency for a Printed Circuit Board (PCB)-based 60 GHz radar. This would have potential for improved low-cost radar lenses for the consumer product market. Method...

ISRU is considered as a necessity for any space architecture-related activity, since its substantial contribution towards mass saving and logistics will enable potential future lunar colonies and allow them to be less earth reliant. The target of this work is to reduce mass, costs and associated risk for human exploration. Success will further incr...

Ultrasonic Additive Manufacturing (UAM) is a hybrid manufacturing process that involves the layer-by-layer ultrasonic welding of metal foils in the solid state with periodic CNC machining to achieve the desired 3D shape. UAM enables the fabrication of metal smart structures, because it allows the embedding of various components into the metal matri...

Additive manufacturing and its related techniques have frequently been put forward as a promising candidate for planetary in-situ manufacturing, from building life-sustaining habitats on the Moon to fabricating various replacements parts, aiming to support future extra-terrestrial human activity. This paper investigates the mechanical behaviour of...

Purpose This paper aims to explore the potential of ultrasonic additive manufacturing (UAM) to incorporate the direct printing of electrical materials and arrangements (conductors and insulators) at the interlaminar interface of parts during manufacture to allow the integration of functional and optimal electrical circuitries inside dense metallic...

This work proposes a new method for the fabrication of Multifunctional Metal Matrix Composite (MMC) structures featuring embedded printed electrical materials through Ultrasonic Additive Manufacturing (UAM). Printed electrical circuitries combining conductive and insulating materials were directly embedded within the interlaminar region of UAM alum...

Ceramic products have been manufactured for many decades via conventional techniques such as extrusion, oven sintering, casting etc. However, these methods have several inherent disadvantages with regards to the shape and structure possible, which limits their application range. The advent of Laser Additive Manufacturing (LAM) is a key enabler in c...

Ultrasonic Additive Manufacturing (UAM) is a hybrid Additive Manufacturing (AM) process that involves layer-by-layer ultrasonic welding of metal foils and periodic machining to achieve the desired shape. Prior investigative research has demonstrated the potential of UAM for the embedding of electronic circuits inside a metal matrix. In this paper,...

The powder bed fusion additive manufacturing process category, consists of a group of key enabling technologies allowing the fabrication of both intrinsic and complex structures for a series of applications, including aerospace and astronautics. The purpose of this investigation was to explore the potential application of in-space additive manufact...

The formation of smart Lab-on-a-Chip (LOC) devices featuring integrated sensing optics is currently hindered by convoluted and expensive manufacturing procedures. In this work, a series of 3D-printed LOC devices were designed and manufactured via stereolithography (SL) in a matter of hours. The spectroscopic performance of a variety of optical fibr...

The purpose of this paper is to investigate the effect of the main process parameters of Laser Melting (LM) type Additive Manufacturing (AM) on multi layered structures manufactured from JSC-1A Lunar regolith (Moondust) simulant powder. Laser diffraction technology was used to analyse and confirm the simulant powder material particle sizes and dis...

Ultrasonic consolidation has been shown to be a viable metal-matrix-based smart composite additive layer manufacturing process. Yet, high quantity fibre integration has presented the requirement for a method of accurate positioning and fibre protection to maintain the fibre layout during ultrasonic consolidation. This study presents a novel approac...

The formation of smart, Metal Matrix Composite (MMC) structures through the use of solid-state Ultrasonic Additive Manufacturing (UAM) is currently hindered by the fragility of uncoated optical fibers under the required processing conditions. In this work, optical fibers equipped with metallic coatings were fully integrated into solid Aluminium mat...

Ultrasonic Additive Manufacturing (UAM) enables the integration of a wide variety of components into solid metal matrices due to the process induced high degree of metal matrix plastic flow at low bulk temperatures. Exploitation of this phenomenon allows the fabrication of previously unobtainable novel engineered metal matrix components.The feasibi...

Ultrasonic Additive Manufacturing (UAM) is an advanced manufacturing technique, which enables the embedding of electronic components and interconnections within solid aluminium structures, due to the low temperature encountered during material bonding. In this study, the effects of ultrasonic excitation, caused by the UAM process, on the electrical...

This chapter explores the ultrasonic additive manufacturing (UAM) advanced solid-state metal additive/subtractive manufacturing process that combines ultrasonic welding and computer numerical control milling to fabricate solid metal components, layer-by-layer, from metal foils. The chapter will discuss the three key abilities of UAM: complicated ge...

Ultrasonic consolidation (UC) has been proven to be a suitable method for fiber embedment into metal matrices. To aid successful embedment of high fiber volumes and to ensure their accurate positioning, research on producing microchannels in combination with adjacent shoulders formed by distribution of the melt onto unique UC sample surfaces with a...

Ultrasonic Additive Manufacturing (UAM) enables the integration of a wide variety of components into solid metal matrices due to a high degree of metal plastic flow at low matrix bulk temperatures. This phenomenon allows the fabrication of previously unobtainable novel engineered metal matrix components. The aim of this paper was to investigate the...

Ultrasonic Additive Manufacturing (UAM), or Ultrasonic Consolidation as it is also referred, is a hybrid form of manufacture, primarily for metal components. The unique nature of the process permits extremely novel functionality to be realised such as multi-material structures with embedded componentry. UAM has been subject to research and investig...

Ultrasonic Consolidation (UC) is a manufacturing technique based on the ultrasonic joining of a sequence of metal foils. It has been shown to be a suitable method for fiber embedment into metal matrices. However, integration of high volume fractions of fibers requires a method for accurate positioning and secure placement to maintain fiber layouts...

Ultrasonic Additive Manufacturing (UAM) has been subject to research and investigation at Loughborough University since 2001. In recent years, three particular areas of significant focus have been: • The influence of pre-process material texture on interlaminar bonding. • Secure fibre positioning through laser machined channels. • Freeform electric...

Ultrasonic Consolidation (UC) is a manufacturing technique based on the ultrasonic metal welding of a sequence of metal foils which are bonded to one another in a layer by layer manner. It combines the ability of additive and subtractive manufacturing techniques to create complex three-dimensional shapes. Due to moderate applied pressures and the r...

Ultrasonic Consolidation (UC) is an additive manufacturing technology which is based on the sequential solid-state ultrasonic welding of metal foils. UC presents a rapid and adaptive alternative process, to other metal-matrix embedding technologies, for ‘smart’ metal composite material production. A challenge that exists however relates to optimisi...

Ultrasonic Consolidation (UC) is a manufacturing technique based on the ultrasonic metal welding of a sequence of metal foils which are bonded to one another in a layer by layer manner. It combines the ability of additive and subtractive manufacturing techniques to create complex three-dimensional shapes. Due to moderate applied pressures and the r...

This is an article from the journal, Proceedings of the IMechE, Part L: Journal of Materials: Design and Applications [© IMechE ]. It is also available at: http://dx.doi.org/10.1243/14644207JMDA268 Future ‘smart’ structures have the potential to revolutionize many engineering applications. One of the possible methods for creating smart structures i...

Timely repair and replacement of military components without degrading material properties offers tremendous opportunities for cost and schedule savings on a number of military platforms. Effective fieldbased additive manufacturing repair approaches have proven difficult to develop, as conventional additive metal deposition technologies typically i...