Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

Hyer, Holden; Sweeney, Dan; Petrie, Christian M.

doi:10.1016/j.addma.2022.102681

Cited by 21 publications

(15 citation statements)

References 44 publications

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“…The potential failure reason could be that the difference in thermal expansion coefficients between SS304 and pure Ni could result in delamination between the Ni foils and the SS304 matrix at higher temperatures. Based on this experience, for the first time, Hyer et al [36] proposed a new method to investigate the processing and microstructure of UAM-fabricated SS304 foils to a SS304 base while simultaneously embedding fiberoptic sensors in the metal matrix, as shown in Figure 14. The UAM processing parameters and foil materials were first varied by using SS304 plates.…”

Section: Embedded Fiber-opticsmentioning

confidence: 99%

Advanced Measurement and Visualization Techniques for High-Temperature Heat Pipe Experiments

Qin

Nuñez

Sellers

et al. 2022

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This report conducts a preliminary investigation of the available literature and summarizes some potential advanced measurement and visualization techniques for operating high-temperature heat pipe (HP) that can be implemented to support the United States (U.S.) Department of Energy (DOE) Microreactor Program (MRP). The primary objective for the extensive literature research is to investigate the possibilities and feasibility for the design and construction of an advanced experimental test facility with the aim of producing high-fidelity high-resolution heat pipe data during its operation.Based on the existing HP test facilities at Idaho National Laboratory (INL)including the Single Primary Heat Extraction and Removal Emulator (SPHERE) and the Microreactor Agile Non-Nuclear Experimental Test Bed (MAGNET)further efforts will be made to examine the technical feasibility to HP measurements and support the research, development, and demonstration (RD&D) process for an HP-cooled microreactor. Continuing collaborations with the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, other research institutes and universities are considered to be extremely important so that the experimental facility and resultant database can satisfy the validation needs of advanced heat pipe modeling codes being developed under DOE NEAMS program. vii

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Section: Embedded Fiber-opticsmentioning

confidence: 99%

Advanced Measurement and Visualization Techniques for High-Temperature Heat Pipe Experiments

Qin

Nuñez

Sellers

et al. 2022

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“…Only of the embedded fibers survived the UAM process. More information on the UAM and fabrication process can be found in previous reports [6,24,25]. Additionally, a high-temperature stain gauge was attached to the face adjacent to the one with the embedded fiber by spot-welding the SS304 flange containing the sensitive portion of the gauge to the hex block with thin Ni-Cr foils over the top of the cabling for strain relief, as shown in Figure 3(b).…”

Section: Sensor Placementmentioning

confidence: 99%

“…At the top of the hex block, the embedded sensors were routed out from the embedded region, as shown in Figure 3(a). The sensors can easily be strained at the entrance to the embedded region during handling, making it a potential failure point-something that was indicated in previous work [15,16,25]. Before ramping to the heat pipe's operational temperature range (>600°C), a series of lower temperature holds were performed at 200, 400, and 500°C to allow the part to reach a uniform temperature and potentially relieve any stress in the fiber at the entrance to the embedded region.…”

Section: Strain Measurementsmentioning

confidence: 99%

“…However, conventional SS processing via casting and subsequent working is not ideal for embedding fragile fiber optics. Therefore, recent studies have used additive manufacturing (AM) to rapidly prototype new component designs with geometric complexities [20,21] and embed fiber-optic sensors during the fabrication process [12,15,16,[22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

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Performance of Microreactor Test Article with Embedded Sensors During Testing in The Single Primary Heat Extraction and Removal Emulator

Hyer

Sweeney

Petrie

et al. 2022

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“…19 This methodology has been used to create multi-material structures with embedded active sensors such as shape memory alloys (SMA) 20,21 for actuation purposes, electrical circuitry 22 and fiber optic sensors for SHM purposes. 23 Hahnlen and Dapino have shown that the temperature of the welding surface during UAM stays below the curie temperature of PVDF which ensures its sensing capabilities. 24 Furthermore, due to its concurrent use with CNC operations, UAM can be used to manufacture the required geometry for successful embedment of sensors without the detrimental effects of temperature-intensive processes.…”

Section: Introductionmentioning

confidence: 99%

Characterization of a PVDF sensor embedded in a metal structure using ultrasonic additive manufacturing

Khattak¹,

Headings

Dapino

2023

NDE 4.0, Predictive Maintenance, Communication, and Energy Systems: The Digital Transformation of NDE

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This paper investigates the characterization and functional performance of a piezoelectric polyvinylidene fluoride (PVDF) sensor embedded into an aluminum plate using ultrasonic additive manufacturing (UAM). While conventional manufacturing techniques such as non-resin-based powder metallurgy are being used to surface-mount smart materials to metals, they pose their own set of problems. Standard manufacturing approaches can physically damage the sensor or deteriorate electrochemical properties of the active material due to high processing temperatures or long adhesive settling times. In contrast, UAM integrates solid-state metal joining with subtractive processes to enable the fabrication of smart structures by embedding sensors, actuators, and electronics in metal-matrices without thermal loading. In this paper, a commercial PVDF sensor is embedded in aluminum with a pre-compression to provide frictional coupling between the sensor and the metal-matrix, thus eliminating the need for adhesives. Axial impact and bending (shaker) tests are conducted on the specimen to characterize the PVDF sensor’s frequency bandwidth and impact detection performance. Metal-matrices with active components have been under investigation to functionalize metals for various applications including aerospace, automotive, and biomedical. UAM embedment of sensors in metals enables functionalization of structures for measurement of stresses and temperature within the structure while also serving to shield smart components from environmental hazards. This technique can serve a wide-range of applications including robotics and tactile sensing, energy harvesting, and structural health monitoring.

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Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

Cited by 21 publications

References 44 publications

Advanced Measurement and Visualization Techniques for High-Temperature Heat Pipe Experiments

Advanced Measurement and Visualization Techniques for High-Temperature Heat Pipe Experiments

Performance of Microreactor Test Article with Embedded Sensors During Testing in The Single Primary Heat Extraction and Removal Emulator

Characterization of a PVDF sensor embedded in a metal structure using ultrasonic additive manufacturing

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