Feasibility study on integrated structural health monitoring system produced by metal three-dimensional printing

Strantza, Maria; Baere, Dieter De; Rombouts, Marleen; Maes, Gert; Guillaume, Patrick; Hemelrijck, Danny Van

doi:10.1177/1475921715604389

Cited by 20 publications

(18 citation statements)

References 24 publications

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“…The further the cross section from the neutral axis, the lower the moment of inertia and the higher the nominal stress and the stress at the capillary becomes. More details on the design strategy can be found in the paper of Strantza et al [ 9 ]. After production the specimens were milled to the final dimensions shown in Figure 2 b.…”

Section: Methodsmentioning

confidence: 99%

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Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods

Strantza

Aggelis

Baere

et al. 2015

Sensors

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During the last decades, structural health monitoring (SHM) systems are used in order to detect damage in structures. We have developed a novel structural health monitoring approach, the so-called “effective structural health monitoring” (eSHM) system. The current SHM system is incorporated into a metallic structure by means of additive manufacturing (AM) and has the possibility to advance life safety and reduce direct operative costs. It operates based on a network of capillaries that are integrated into an AM structure. The internal pressure of the capillaries is continuously monitored by a pressure sensor. When a crack nucleates and reaches the capillary, the internal pressure changes signifying the existence of the flaw. The main objective of this paper is to evaluate the crack detection capacity of the eSHM system and crack location accuracy by means of various non-destructive testing (NDT) techniques. During this study, detailed acoustic emission (AE) analysis was applied in AM materials for the first time in order to investigate if phenomena like the Kaiser effect and waveform parameters used in conventional metals can offer valuable insight into the damage accumulation of the AM structure as well. Liquid penetrant inspection, eddy current and radiography were also used in order to confirm the fatigue damage and indicate the damage location on un-notched four-point bending AM metallic specimens with an integrated eSHM system. It is shown that the eSHM system in combination with NDT can provide correct information on the damage condition of additive manufactured metals.

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Section: Methodsmentioning

confidence: 99%

“…The size of the capillaries can currently vary between 1 and 3 mm in diameter. The response of the structure with and without capillary is demonstrated in [ 9 ] where the eSHM system has proven its effectiveness. The eSHM system does not influence the crack initiation behavior and as a result the fatigue life as it is shown in [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods

Strantza

Aggelis

Baere

et al. 2015

Sensors

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“…With over 40 fatigue tests conducted, the eSHM has always successfully detected the fatigue cracks prior to complete fracture. Strantza et al [3] presented that the eSHM system has reached TRL level 3. The capillaries of the eSHM system were produced either using laser based Directed Energy Deposition (DED) [4,5] or laser based Powder Bed Fusion (PBF) [6].…”

Section: Introductionmentioning

confidence: 99%

Fatigue Performance of Powder Bed Fused Ti-6Al-4V Component with Integrated Chemically Etched Capillary for Structural Health Monitoring Application

Hinderdael

Baere

Guillaume

2018

The 18th International Conference on Experimental Mechanics

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Fatigue performance of additively manufactured (AM) components is still uncertain and inconsistent. Structural health monitoring (SHM) systems offer a solution to continuously monitor the structural integrity of a structure. The effective Structural Health Monitoring (eSHM) system is the first SHM principle developed with the principal purpose to monitor AM components. The eSHM principle exploits the design freedom offered by AM to integrate a capillary inside the component. The capillary is put under low vacuum and the pressure is monitored during the operation of the component. As-built AM surfaces report elevated surface roughness and are one of the principle causes of premature fatigue initiation and fatigue failure. The current study will investigate the effect of a chemical etching (CE) post-process on the capillary surface and evaluate its effect on the fatigue performance.

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“…It was concluded in the paper of Strantza et al [9] that-for the considered structure in the paper-the presence of the capillary did not influence the fatigue life negatively, although the cracks initiated from the capillary when positioned close to the specimen edge. Another paper of Strantza et al [10] reported on four point bending test results of test samples with a different layout of the embedded capillaries. It was concluded that the capillary had no crucial influence on the fatigue initiation location for the test specimen and test conditions under investigation.…”

Section: Effective Structural Health Monitoring Systemmentioning

confidence: 99%

Proof of Concept of Crack Localization Using Negative Pressure Waves in Closed Tubes for Later Application in Effective SHM System for Additive Manufactured Components

2016

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Additive manufactured components have a different metallurgic structure and are more prone to fatigue cracks than conventionally produced metals. In earlier papers, an effective Structural Health Monitoring solution was presented to detect fatigue cracks in additive manufactured components. Small subsurface capillaries are embedded in the structure and pressurized (vacuum or overpressure). A crack that initiated at the component's surface will propagate towards the capillary and finally breach it. One capillary suffices to inspect a large area of the component, which makes it interesting to locate the crack on the basis of the pressure measurements. Negative pressure waves (NPW) arise from the abrupt encounter of high pressure fluid with low pressure fluid and can serve as a basis to locate the crack. A test set-up with a controllable leak valve was built to investigate the feasibility of using NPW to localize a leak in closed tubes with small lengths. Reflections are expected to occur at the ends of the tube, possibly limiting the localization accuracy. In this paper, the results of the tests on the test set-up are reported. It will be shown that the crack could be localized with high accuracy (millimeter accuracy) which proves the concept of crack localization on basis of NPW in a closed tube of small length.

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Feasibility study on integrated structural health monitoring system produced by metal three-dimensional printing

Cited by 20 publications

References 24 publications

Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods

Evaluation of SHM System Produced by Additive Manufacturing via Acoustic Emission and Other NDT Methods

Fatigue Performance of Powder Bed Fused Ti-6Al-4V Component with Integrated Chemically Etched Capillary for Structural Health Monitoring Application

Proof of Concept of Crack Localization Using Negative Pressure Waves in Closed Tubes for Later Application in Effective SHM System for Additive Manufactured Components

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