Ultrasonic additive manufacturing of zirconium: Pilot results

[Display omitted] •The application of UAM to HCP materials requires higher interfacial temperatures.•Increased plasticity at higher deformation temperature minimized interface porosity.•Bond strengths in build direction 80% of that measured in perpendicular directions.•Post-build texture differs from conventionally rolled HCP materials. Ultrasonic additive manufacturing (UAM) was successfully applied to the Zirconium material system to create a three-dimensional component prototype. The UAM process resulted in grain size refinement and significant localized deformation. Electron backscatter diffraction analysis revealed activated slip systems only applicable at high deformation temperatures, while texture analysis showed a decrease in measurable texture of the UAM build in comparison to the initial Zr-foil. Average tensile strengths in the X (sonotrode travel), Y (vibration), and Z (build) directions averaged 435 MPa, 458 MPa, and 359 MPa, respectively, demonstrating the viability of UAM for Zr-based materials. The delamination of some Z specimens along foil boundaries during loading suggests an interplay between interfacial Ti impurities introduced during welding and the spatial dependence of weld quality for this material system.