Smart Build-Plate for Metal Additive Manufacturing Processes

Abstract

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.

In-situ measurement and monitoring methods for metal powder bed fusion: an updated review

“…In Dunbar et al (2016), a displacement sensor was attached to the underside of the baseplate. A more recent study (Hehr et al 2020) presented a smart baseplate for L-PBF with an embedded optical fibre strain measurement sensor.…”

“…Rather than measuring the baseplate deformation, Hehr et al (2020) demonstrated the feasibility of the proposed approach to detect plastic deformations like a delamination from the baseplate.…”

Embedded Sensors for Structural Health Monitoring: Methodologies and Applications Review

“…Over the last few years and based on techniques of incorporation of FOSs, a set of systems has been developed that allows the monitoring of strains, temperature variations and cracking, using mainly FOSs of FBG type [76][77][78][79][80][81][82][83][84][85]. Xiao Chun Li et al [76][77][78][79] is one of the main boosters in the development of methodologies capable of integrating sensors into metal components, using in this case, low-temperature processes, magnetron sputtering and electroplating.…”

“…Schomer et al [81], Chilelli et al [84] and Hehr et al [85] demonstrated the feasibility of integrating FOSs into metal matrices through UAM and monitoring temperature, cracks and residual stress, respectively, into structural components. This type of process also has great potential to monitor components present in environments subject to high temperatures, which does not happen with piezoelectric sensors as further forward will be analysed.…”

“…These technologies are the Shape Deposition Manufacturing (Figure 11 a)), the Electron Beam Melting (Figure 11 b)), the Magnetron sputtering and Electroplating (Figure 11 c)), and the Ultrasonic Additive Manufacturing (Figure 11 d)). [76][77][78][79][80][81][82][83][84][85]105,106,108,109,[122][123][124][125][126][130][131][132][133].…”