Integrating Fiber Optic Strain Sensors into Metal Using Ultrasonic Additive Manufacturing

Hehr, Adam; Norfolk, Mark; Wenning, Justin; Sheridan, John T.; Leser, Paul; Leser, Patrick E.; Newman, John A.

doi:10.1007/s11837-017-2709-8

Cited by 58 publications

(27 citation statements)

References 7 publications

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“…UAM has been used to fabricate soft materials, such as Al alloys [11,12], harder materials, such as copper [13][14][15], nickel [16], steel [17,18] and titanium [19][20][21], dissimilar materials, such as Al-Ti [21], Al-Cu [15], Al-steel [22], Al-NiTi [23,24], Al-MetPreg (a fibre-reinforced aluminium) [25][26][27] and Ni-steel [18] and metal matrix composite with embedded elements, such as SiC fibres [28,29], shape memory alloy fibres [30], dielectric materials (used in printed circuit board) [31], electronic circuitry [32], glass fibres and fibre optic sensors [33][34][35] and carbon fibres [36].…”

Section: Introductionmentioning

confidence: 99%

A review of microstructure evolution during ultrasonic additive manufacturing

2021

Int J Adv Manuf Technol

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Ultrasonic additive manufacturing (UAM) is a solid-state metal additive manufacturing process, with the combination of layer by layer ultrasonic seam welding and CNC machining. Due to the friction and deformation at the bonding interface, the ultrasonic softening effect and temperature generated, the microstructure of the substrate materials is evolving constantly. In this paper, in order to better understand the bonding mechanisms, the good practice and the capability of UAM, and the influence of different key process parameters on bonding quality, the microstructure evolution during UAM is reviewed in detail. Defects can be generated at the UAM bonding interface, but by choosing the right material combination and the right process parameters, defects can be reduced to minimum. Plastic deformation is very important for the bonding between layers during UAM, and plastic flow is important for redistribution of oxide layer, forming of mechanical interlocks, filling micro-valleys on the mating surface, and filling the gaps when embedding elements. UAM process can cause recrystallization and grain refinement at the welding interface and the intimate bulk materials around, and it will also gradually change the texture from rolling texture to shear texture. In the meantime, when further layers of materials are deposited on the top of the existing part, the microstructure will have some accumulative change. In order to reduce the defects number and increase the strength, sometimes, heat treatment needs to be carried out to the as-deposited parts, which will change the microstructure as well. Finally, the relevant research is summarised and the perspectives of further research are recommended.

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Section: Introductionmentioning

confidence: 99%

A review of microstructure evolution during ultrasonic additive manufacturing

2021

Int J Adv Manuf Technol

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“…Fiber optic based strain sensors that were limited to external mounting on metallic structures can now be incorporated into structures with the advent of metal additive manufacturing [9][10][11][12]. UAM, a low-temperature metal additive-manufacturing technology, overcomes formation challenges found in directed energy deposition type processes and has successfully been used to build fiber optic Bragg gratings (FBGs) and HD-FOS into metal components for monitoring purposes [13][14][15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

Smart Build-Plate for Metal Additive Manufacturing Processes

Hehr¹,

Norfolk²,

Kominsky

et al. 2020

Sensors

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This paper discusses the development, processing steps, and evaluation of a smart build-plate or baseplate tool for metal additive manufacturing technologies. This tool uses an embedded high-definition fiber optic sensing fiber to measure strain states from temperature and residual stress within the build-plate for monitoring purposes. Monitoring entails quality tracking for consistency along with identifying defect formation and growth, i.e., delamination or crack events near the build-plate surface. An aluminum alloy 6061 build-plate was manufactured using ultrasonic additive manufacturing due to the process’ low formation temperature and capability of embedding fiber optic sensing fiber without damage. Laser-powder bed fusion (L-PBF) was then used to print problematic geometries onto the build-plate using AlSi10Mg for evaluation purposes. The tool identified heat generation, delamination onset, and delamination growth of the printed L-PBF parts.

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“…Sapphire fiber-based sensors could extend the operational temperature range to 1,500°C or higher [16][17][18][19], although these sensors have a relatively low technology readiness level. Fiber-optic sensors are also being considered for spatially distributed strain measurements based on success performing similar measurements after embedding the sensors in metals [20][21][22].…”

Section: Introductionmentioning

confidence: 99%