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Sensors (Basel). 2020 Jan 8;20(2). pii: E360. doi: 10.3390/s20020360.

Smart Build-Plate for Metal Additive Manufacturing Processes.

Author information

1
Fabrisonic LLC, Columbus, OH 43221, USA.
2
Luna Innovations Inc., Blacksburg, VA 24060, USA.
3
Edison Welding Institute (EWI), Columbus, OH 43221, USA.

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.

KEYWORDS:

HD-FOS; L-PBF; UAM; additive manufacturing; embedded sensing; fiber optic

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