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.
Highlights
Additive manufacturing (AM) has rapidly evolved into a valuable technique for producing parts that, at times, cannot be fabricated through conventional machining methods
Hidden flaws in a part, which can be caused by excessive residual stresses, can result in the final part being unusable, and wasting valuable time, resources, and AM machine life
Strain measurements in the High-definition fiber optic sensors sensors (HD-FOS) fiber were made using Rayleigh scatter from the studies
Summary
Additive manufacturing (AM) has rapidly evolved into a valuable technique for producing parts that, at times, cannot be fabricated through conventional machining methods. One challenge in AM is the lack of real-time feedback on the fabrication process and the quality of the part being made This is especially critical given the relatively long periods of time that complex parts can require to be constructed. Hidden flaws in a part, which can be caused by excessive residual stresses, can result in the final part being unusable, and wasting valuable time, resources, and AM machine life. At this point in time, damage events in parts are curtailed or quantified using experimental build-and-check standardization techniques. Nondestructive evaluation techniques, including array eddy current and X-ray imaging, have been demonstrated for in situ monitoring of near-subsurface volumetric quality and process phenomena (e.g., melt-pool dynamics, solidification, keyholing), respectively [5,6]
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