Optical fibre sensing in metals by embedment in 3D printed metallic structures

Maier, Robert R. J.; Havermann, Dirk; Schneller, Oliver; Mathew, Jinesh; Polyzos, D.; MacPherson, William N.; Hand, Duncan Paul

doi:10.1117/12.2064886

Cited by 8 publications

(5 citation statements)

References 12 publications

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“…Embedding of fiber optic sensors in metallic materials has been investigated by many researchers [ 8 , 86 , 87 , 88 , 89 , 90 ]. One of the objectives for this type of materials is to embed an FBG array optical fibers in multiple direction covering 3D space inside the material.…”

Section: Materials Behaviormentioning

confidence: 99%

“…Maier et al [ 87 ] used additive manufacturing to embed sensors in metallic structures. These embedded sensors would be capable of operating at extremely high temperatures by utilizing regenerated fiber Bragg gratings and in-fiber Fabry-Perot cavities [ 87 ]. Taylor et al [ 88 ] and Lee et al [ 89 ] used casting to embed a fiber Fabry-Perot Interferometer into aluminum.…”

Section: Materials Behaviormentioning

confidence: 99%

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Fiber-Embedded Metallic Materials: From Sensing towards Nervous Behavior

Saheb

Mekid

2015

Materials

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Embedding of fibers in materials has attracted serious attention from researchers and has become a new research trend. Such material structures are usually termed “smart” or more recently “nervous”. Materials can have the capability of sensing and responding to the surrounding environmental stimulus, in the former, and the capability of feeling multiple structural and external stimuli, while feeding information back to a controller for appropriate real-time action, in the latter. In this paper, embeddable fibers, embedding processes, and behavior of fiber-embedded metallic materials are reviewed. Particular emphasis has been given to embedding fiber Bragg grating (FBG) array sensors and piezo wires, because of their high potential to be used in nervous materials for structural health monitoring. Ultrasonic consolidation and laser-based layered manufacturing processes are discussed in detail because of their high potential to integrate fibers without disruption. In addition, current challenges associated with embedding fibers in metallic materials are highlighted and recommendations for future research work are set.

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Section: Materials Behaviormentioning

confidence: 99%

Section: Materials Behaviormentioning

confidence: 99%

Fiber-Embedded Metallic Materials: From Sensing towards Nervous Behavior

Saheb

Mekid

2015

Materials

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“…For example, when knowledge of mechanical signals inside the structure is needed, sensors bonded on the outside can no longer be used. In addition, the embedded sensor can demonstrate stronger applicability for structures functioning in harsh conditions, such as corrosive environments, which may disable external sensors [2]. The need for information inside the structure in sectors including aerospace [2] demands reliable technology for embedding sensors within structures.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, the embedded sensor can demonstrate stronger applicability for structures functioning in harsh conditions, such as corrosive environments, which may disable external sensors [2]. The need for information inside the structure in sectors including aerospace [2] demands reliable technology for embedding sensors within structures. There are two main approaches to embedding a sensor within a structure.…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive Study on Measurement Accuracy of Distributed Fiber Optic Sensors Embedded within Capillaries of Solid Structures

Xiao,

Rans,

Zarouchas

et al. 2023

Sensors

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Embedding fiber optic sensors (FOSs) within parts for strain measurement is attracting widespread interest due to its great potential in the field of structural health monitoring (SHM). This work proposes a novel method of embedding FOSs using capillaries within solid structures and investigates fiber positions and orientation uncertainties within capillaries of different sizes and their influences on strain measurement accuracies. To investigate how the fiber positions and orientation variations influence strain measurement accuracy, both analytical and numerical models are utilized to predict strain distributions along embedded fibers at different positions and with different orientations within the specimen. To verify the predictions, a group of specimens made of Aluminum 6082 was prepared, and the specimens in each group had capillaries of 2 mm, 4 mm, and 6 mm diameters, respectively. Fibers were embedded within each specimen using the capillaries. Four-point bending static tests were conducted for each specimen with embedded FOSs, performing in situ strain measurement. Subsequently, the specimens were partitioned into several pieces, and the cross sections were observed to know the real positions of the embedded fiber. Finally, the strain predictions at the real locations of the fiber were compared with the measured strain from the embedded FOSs. The predicted strain distributions as a function of the fiber positions alone and as a function of both the fiber positions and orientations were compared to assess the influence of fiber orientation change. The results from a combination of analytical, numerical, and experimental techniques suggest that the fiber position from the capillary center is the main factor that can influence strain measurement accuracies of embedded FOSs, and potential fiber misalignments within the capillary had a negligible influence. The fiber position-induced measured error increases from 10.5% to 18.5% as the capillary diameter increases from 2 mm to 6 mm. A 2 mm capillary diameter is able to lead to the lowest measurement error in this study and maintains ease of embedding. In addition, it is found that the measured strain always lies within a strain window defined by the strain distribution along capillary boundaries when there are no cracks. This can be further studied for crack detection.

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“…Selective laser melting (SLM) has been used to embed FBG sensors; however, the residual stresses left by this process tend to induce sensor damage along with poor coupling between the sensor and matrix [14,15]. Some investigations have demonstrated better AM embedment through the use of fibers with specialized coatings [16,17,18].…”

Section: Introductionmentioning

confidence: 99%

Detection of Crack Initiation and Growth Using Fiber Bragg Grating Sensors Embedded into Metal Structures through Ultrasonic Additive Manufacturing

Chilelli

Schomer

Dapino

2019

Sensors

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Structural health monitoring (SHM) is a rapidly growing field focused on detecting damage in complex systems before catastrophic failure occurs. Advanced sensor technologies are necessary to fully harness SHM in applications involving harsh or remote environments, life-critical systems, mass-production vehicles, robotic systems, and others. Fiber Bragg Grating (FBG) sensors are attractive for in-situ health monitoring due to their resistance to electromagnetic noise, ability to be multiplexed, and accurate real-time operation. Ultrasonic additive manufacturing (UAM) has been demonstrated for solid-state fabrication of 3D structures with embedded FBG sensors. In this paper, UAM-embedded FBG sensors are investigated with a focus on SHM applications. FBG sensors embedded in an aluminum matrix 3 mm from the initiation site are shown to resolve a minimum crack length of 0.286 ± 0.033 mm and track crack growth until near failure. Accurate crack detection is also demonstrated from FBGs placed 6 mm and 9 mm from the crack initiation site. Regular acrylate-coated FBG sensors are shown to repeatably work at temperatures up to 300 ∘C once embedded with the UAM process.

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Optical fibre sensing in metals by embedment in 3D printed metallic structures

Cited by 8 publications

References 12 publications

Fiber-Embedded Metallic Materials: From Sensing towards Nervous Behavior

Fiber-Embedded Metallic Materials: From Sensing towards Nervous Behavior

A Comprehensive Study on Measurement Accuracy of Distributed Fiber Optic Sensors Embedded within Capillaries of Solid Structures

Detection of Crack Initiation and Growth Using Fiber Bragg Grating Sensors Embedded into Metal Structures through Ultrasonic Additive Manufacturing

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