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.
The reliability of electrical equipment in high voltage systems can be affected by certain defaults (metallic particles, roughness, etc.) inside the device enclosure. These anomalies may cause a local glow discharge which propagates progressively inside the insulator and which can lead to electrical breakdown. To avoid this end result, corona discharges have to be detected with a system which satisfies some requirements. Actual methods are not well adapted to industrial constraints. An optoelectronic setup, consisting of a fluorescent plastic optical fiber as a light sensor, connected to a simple, low-cost amplifier, is proposed. Measurements were first carried out in air to demonstrate the feasibility of this detection method, then air was replaced by SF6. Results lead to the delineation of a sensor made of the fluorescent fiber and the associated amplifier.
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