Direct joining of 3D-printed thermoplastic parts to SLM-fabricated metal cellular structures by ultrasonic welding

The joining capability of metal cellular structures fabricated using the additive manufacturing (selective laser melting (SLM)) method is investigated herein. The metal cellular structures are composed of sub-millimeter holes and internal pores. The direct joining of 3D-printed ABS-M30i thermoplastic parts to metal cellular structures by ultrasonic welding is demonstrated. The SLM-fabricated structures comprised of partially melted powders provide micro-scale roughness, which enhances the micro-mechanical interlocking between joining parts. A shear strength 17.7MPa and normal tensile strength of 15.2MPa were obtained, up to 55 and 48% of ABS-M30i ultimate tensile strength, respectively. Moreover, normal tensile plastic strength up to 86% of the shear strength was obtained.