Embedded Fiber Optic Sensors Within Additive Layer Manufactured Components

Maier, Robert R. J.; MacPherson, William N.; Barton, James S.; Carne, Margaret; Swan, M.; Sharma, Jaibir; Futter, S K; Knox, David; Jones, Benjamin; McCulloch, Scott

doi:10.1109/jsen.2012.2226574

Cited by 42 publications

(21 citation statements)

References 8 publications

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“…In situ measurements offer potential to enhance asset management, including lifetime monitoring, and the safe use of components closer to their design limits of mechanical stability [1]. Predominately, embedding of fibre optic sensors has been demonstrated either in structures manufactured from composite materials [2] and plastics [3] or by utilising epoxy adhesion for bonding to metal materials [4], all of which are systems which limit the usable temperature range to temperatures below maximum 350°C.…”

Section: Introductionmentioning

confidence: 99%

Temperature and Strain Measurements With Fiber Bragg Gratings Embedded in Stainless Steel 316

Havermann

Mathew

MacPherson

et al. 2015

J. Lightwave Technol.

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Single-mode optical fibers with thin nickel coatings (outer diameter ∼350 μm) are successfully embedded into stainless steel (SS) 316 components using bespoke laser-based additive manufacturing technology. In our approach, we manufacture SS 316 components using selective laser melting, incorporating U-shaped grooves with dimensions suitable to hold nickel-coated optical fibers. Coated optical fibers containing fiber Bragg gratings for strain monitoring and temperature sensing are placed in the groove. The embedding is completed by melting subsequent powder layers on top of the fibers. Cross-sectional microscopy analysis of the fabricated components, together with analysis of the Bragg gratings behavior during fabrication indicates a strong substanceto-substance bond between coated fiber and added SS 316 material. Temperature and strain cycling of the embedded sensors demonstrates the ability of gratings to survive the embedding process, and act as sensing elements in harsh environments. In situ strain and temperature measurements from within the component are demonstrated for high dynamic stress levels and elevated temperatures (<400°C).Index Terms-Bragg gratings, embedded fiber sensors, laser melting, laser sintering, optical fiber sensors, stainless steel, strain sensors, temperature sensors. 0733-8724

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Section: Introductionmentioning

confidence: 99%

Temperature and Strain Measurements With Fiber Bragg Gratings Embedded in Stainless Steel 316

Havermann

Mathew

MacPherson

et al. 2015

J. Lightwave Technol.

Self Cite

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“…7 FBGs were also embedded into a polymeric sample made through selective laser sintering, an additive process in which powders are fused via a laser, and comparative strain measurements were taken from the FBG, an extensometer, and an externally mounted foil gage. 8 In the latter study, the sintering process temperatures were high enough to cause degradation of acrylate coated FBGs.…”

Section: Introductionmentioning

confidence: 94%

Characterization of embedded fiber optic strain sensors into metallic structures via ultrasonic additive manufacturing

2016

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Fiber Bragg Grating (FBG) sensors measure deviation in a reflected wavelength of light to detect in-situ strain. These sensors are immune to electromagnetic interference, and the inclusion of multiple FBGs on the same fiber allows for a seamlessly integrated sensing network. FBGs are attractive for embedded sensing in aerospace applications due to their small noninvasive size and prospect of constant, real-time nondestructive evaluation. In this study, FBG sensors are embedded in aluminum 6061 via ultrasonic additive manufacturing (UAM), a rapid prototyping process that uses high power ultrasonic vibrations to weld similar and dissimilar metal foils together. UAM was chosen due to the desire to embed FBG sensors at low temperatures, a requirement that excludes other additive processes such as selective laser sintering or fusion deposition modeling. In this paper, the embedded FBGs are characterized in terms of birefringence losses, post embedding strain shifts, consolidation quality, and strain sensing performance. Sensors embedded into an ASTM test piece are compared against an exterior surface mounted foil strain gage at both room and elevated temperatures using cyclic tensile tests.

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“…In 2013 the authors presented embedded FBGs in polymer materials using a commercial SLM system and reported on the long term performance and stability of such embedded sensors [9] . This work indicated that the modern AM processes appear to be compatible with fibre embedding.…”

Section: Fibre Optic Sensors In Metalsmentioning

confidence: 99%

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

et al. 2014

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Additive manufacturing or 3D printing of structural components in metals has potential to revolutionise the manufacturing industry. Embedded sensing in such structures opens a route towards SMART metals, providing added functionality, intelligence and enhanced performance in many components. Such embedded sensors would be capable of operating at extremely high temperatures by utilizing regenerated fibre Bragg gratings and in-fibre Fabry-Perot cavities.

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Embedded Fiber Optic Sensors Within Additive Layer Manufactured Components

Cited by 42 publications

References 8 publications

Temperature and Strain Measurements With Fiber Bragg Gratings Embedded in Stainless Steel 316

Temperature and Strain Measurements With Fiber Bragg Gratings Embedded in Stainless Steel 316

Characterization of embedded fiber optic strain sensors into metallic structures via ultrasonic additive manufacturing

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

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