Embedding electronics into additive manufactured components using laser metal deposition and selective laser melting

Petrat, T.; Kersting, Robert; Graf, Benjamin; Rethmeier, Michael

doi:10.1016/j.procir.2018.08.071

Cited by 16 publications

(3 citation statements)

References 10 publications

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“…This drawback regarding sensor positioning can be mitigated by laser powder bed fusion (LPBF) technology. It enables the integration and precise positioning of sensors into metallic components, as presented conceptionally by Lehmhus et al [3,4] and shown practically among others by Petrat et al [5] for electronic components, e.g. an LED, Stoll et al [6] for temperature sensors and Maier et al [7], Mathew et al [8], Stoll et al [9] for optical fibers.…”

Section: Motivation and Visionmentioning

confidence: 99%

Embedding eddy current sensors into LPBF components for structural health monitoring

Stoll

Gasparin²,

Spierings

et al. 2021

Prog Addit Manuf

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Laser powder bed fusion (LPBF) facilitates the integration of external elements like sensors into workpieces during manufacturing. These embedded components enable e.g. part monitoring, thus being a fundamental application of industry 4.0. This study assesses the feasibility of embedding eddy current (EC) sensors for non-destructive testing (NDT) into SLM components aiming at structural health monitoring (SHM). A reliable embedding process for EC sensors is developed, ensuring the survivability of the sensors for the LPBF process and its harsh conditions. The experiments conducted demonstrate the possibility to use the embedded EC sensor to observe and detect a controlled crack growth. The cracks are realized either with direct EDM cutting or on the course of a fatigue test of CT specimens. The data retrieved by the embedded EC sensors are proven to provide a direct information about the severity of a damage and its evolution over time for both approaches. Thus, supporting the validation of such an innovative and promising SHM concept.

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Section: Motivation and Visionmentioning

confidence: 99%

Embedding eddy current sensors into LPBF components for structural health monitoring

Stoll

Gasparin²,

Spierings

et al. 2021

Prog Addit Manuf

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“…Although much research has been conducted on aluminum alloys in terms of separate AM, there is little research available on the preparation process combining SLM and DED. It is instructive that Petrat et al [25] integrated LEDs into metal components of AM by combining SLM and DED, which proves that the combination of the two techniques has certain practical application value.…”

Section: Introductionmentioning

confidence: 98%

Microstructure and Mechanical Properties of a Combination Interface between Direct Energy Deposition and Selective Laser Melted Al-Mg-Sc-Zr Alloy

Cao

Yuan

et al. 2021

Metals

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Selective laser melting (SLM) and direct energy deposition (DED) are two widely used technologies in additive manufacturing (AM). However, there are few studies on the combination of the two technologies, which can synthetically combine the advantages of the two technologies for more flexible material design. This paper systematically studies the Al-Mg-Sc-Zr alloy by combination of SLM and DED with emphasis on its bonding properties, microstructure, and metallurgical defects. It is found that the aluminum alloy prepared by the two methods achieves a good metallurgical combination. The microstructure of aluminum alloy prepared by DED is composed of equiaxed crystals, and there are a large number of Al3(Sc, Zr) precipitated phase particles rich in Sc and Zr. The microstructure of SLM aluminum alloy is composed of equiaxed crystals and columnar crystals, and there is a fine-grained area at the boundary of the molten pool. With the decrease of laser volumetric energy density (VED), the width and depth of the molten pool at the interface junction gradually decrease. The porosity gradually increases with the decrease of VED, and the microhardness shows a downward trend. Tensile strength and elongation at fracture of the SLM printed sample at 133.3 J/mm3 are about 400 MPa and 9.4%, while the direct energy depositioned sample are about 280 MPa and 5.9%. Due to the excellent bonding performance, this research has certain guiding significance for SLM–DED composite aluminum alloy.

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“…On the contrary, component integrations in metal additive processes have been less common due to the high temperatures required for melting different alloys -often destroying all but the simplest high temperature sensors. Of the successful attempts to embed components in metal objects; electron beam melting was used for a ceramic sensor [45]; sheet lamination was used and provides the lowest processing temperature of any metal additive manufacturing with ultrasonic welding of metal tape strips together [37,46]; a combination of selective laser melting and directed energy deposition was used in a clever multi-process approach in [47]; and the earliest case in 2000 with a form of directed energy deposition referred to as shape deposition manufacturing [48] -prior to the standardization of terminology with ISO/ASTM 52900 [49]. Sensors were welded onto directed energy deposition structures in this case.…”

Section: Introductionmentioning

confidence: 99%

Embedding ceramic components in metal structures with hybrid directed energy deposition

Feldhausen

Yelamanchi

Gomez

et al. 2023

Int J Adv Manuf Technol

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The combined bene t of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface nish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including: (1) to create complex interwoven ductile / brittle composites for ballistics, or (2) to integrate high temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. In this work, steel substrates were machined to create an internal cavity for insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted and different sequences were continued to envelop the inserted ceramic with varying success. Unmelted powder served as both a thermal buffer and to provide a ush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet) providing stability and minimizing displacement caused by the gas ow. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic, and consequently, improved the survival of the inserts. With this combination of techniques, ceramic inserts survived full embedding within a complex steel structure.

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Embedding electronics into additive manufactured components using laser metal deposition and selective laser melting

Cited by 16 publications

References 10 publications

Embedding eddy current sensors into LPBF components for structural health monitoring

Embedding eddy current sensors into LPBF components for structural health monitoring

Microstructure and Mechanical Properties of a Combination Interface between Direct Energy Deposition and Selective Laser Melted Al-Mg-Sc-Zr Alloy

Embedding ceramic components in metal structures with hybrid directed energy deposition

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