Additively Manufactured Components With Embedded Instrumentation

2016 ◽  
Author(s):  
Matthew Davis ◽  
John Middendorf ◽  
Naman Garg ◽  
Osgar John Ohanian
Keyword(s):  
Additive Manufacturing ◽  
Residual Stresses ◽  
Fiber Optic ◽  
Fiber Reinforced Polymers ◽  
High Definition ◽  
Reinforced Polymers ◽  
Sensing Technology ◽  
Component Design ◽  
Residual Strains ◽  
Printing Processes

Additively manufactured components enable complex structures to be rapidly fabricated and tested for use in the automotive and aerospace industries. Additive manufacturing capabilities have expanded to include a variety of plastics, metal alloys, and fiber-reinforced polymers. There is interest in quantifying the residual stresses in components that have been manufactured using 3D printing processes in order to refine fabrication parameters and improve the performance of component design. Luna Innovations has developed and demonstrated methods to embed high definition fiber optic sensing (HD-FOS) technology into components that have been additively manufactured using ABS plastic as well as a cobalt chrome alloy. This technology enables characterization of internal residual stresses and provides a method for lifetime health monitoring of these printed components using the strain and temperature sensors installed during printing. The sensing technology utilizes the Rayleigh backscatter pattern contained in an optical fiber to determine the strain or temperature, with a high spatial resolution of 1.28 mm, along a fiber that can be embedded inside a printed component. HD-FOS technology was used to measure internal residual strains within layers of varying depths of an ABS printed block, showing a parabolic strain profile with a peak at 9,600 microstrain. In addition to characterizing the printing process, a method has been demonstrated to embed a distributed temperature sensor into a metallic additively manufactured component. This enables the temperature of the part to be measured while it is in use, providing data on the heat transfer through the component. Additive manufacturing has enabled embedding fiber optic sensors in new configurations that were previously unobtainable.

Mechanical properties of fiber reinforced polymer composites: A comparative study of conventional and additive manufacturing methods

2018 ◽  
Vol 52 (23) ◽  
pp. 3173-3181 ◽  
Author(s):  
Kuldeep Agarwal ◽  
Suresh K Kuchipudi ◽  
Benoit Girard ◽  
Matthew Houser
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fiber Reinforced Polymer ◽  
Fiber Reinforced Polymers ◽  
Manufacturing Processes ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Reinforced Polymer ◽  
Fiber Reinforced Polymer Composites ◽  
Composite Filament

Fiber reinforced polymer composites have been around for many decades but recently their use has started to increase in multiple industries such as automotive, aerospace, and construction. The conventional composite manufacturing processes such as wet lay-up, resin transfer molding, automatic lay ups etc. suffer from a lot of practical and material issues which have limited their use. The mechanical properties of the parts produced by such processes also suffer from variation that causes problems downstream. Composites based additive manufacturing processes such as Fused Deposition Modeling and Composite Filament Fabrication are trying to remove some of the barriers to the use of composites. Additive manufacturing processes offer more design and material freedom than conventional composite manufacturing processes. This paper compares conventional composite processes for the manufacturing of Epoxy-Fiberglass fiber reinforced polymers with composite filament fabrication based Nylon-Fiberglass fiber reinforced polymers. Mechanical properties such as tensile strength, elastic modulus, and fatigue life are compared for the different processes. The effect of process parameters on these mechanical properties for the composite filament fabrication based process is also examined in this work. It is found that the composite filament fabrication based process is very versatile and the parts manufactured by this process can be used in various applications.

scholarly journals State-of-the-art of fiber-reinforced polymers in additive manufacturing technologies

2017 ◽  
Vol 36 (15) ◽  
pp. 1061-1073 ◽  
Author(s):  
Thomas Hofstätter ◽  
David B Pedersen ◽  
Guido Tosello ◽  
Hans N Hansen
Keyword(s):  
Additive Manufacturing ◽  
State Of The Art ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Material Technology ◽  
Reinforced Polymers ◽  
Recent Developments ◽  
Multiple Materials ◽  
Manufacturing Technologies ◽  
Fiber Reinforced Material

Additive manufacturing technologies have received a lot of attention in recent years for their use in multiple materials such as metals, ceramics, and polymers. The aim of this review article is to analyze the technology of fiber-reinforced polymers and its implementation with additive manufacturing. This article reviews recent developments, ideas, and state-of-the-art technologies in this field. Moreover, it gives an overview of the materials currently available for fiber-reinforced material technology.

scholarly journals Additive Re-Manufacturing of Mechanically Recycled End-of-Life Glass Fiber-Reinforced Polymers for Value-Added Circular Design

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3545
Author(s):  
Alessia Romani ◽  
Andrea Mantelli ◽  
Raffaella Suriano ◽  
Marinella Levi ◽  
Stefano Turri
Keyword(s):  
Additive Manufacturing ◽  
Glass Fiber ◽  
End Of Life ◽  
Glass Fibers ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Glass Fiber Reinforced Polymers ◽  
Glass Fiber Reinforced ◽  
Circular Design

Despite the large use of composites for industrial applications, their end-of-life management is still an open issue for manufacturing, especially in the wind energy sector. Additive manufacturing technology has been emerging as a solution, enhancing circular economy models, and using recycled composites for glass fiber-reinforced polymers is spreading as a new additive manufacturing trend. Nevertheless, their mechanical properties are still not comparable to pristine materials. The purpose of this paper is to examine the additive re-manufacturing of end-of-life glass fiber composites with mechanical performances that are comparable to virgin glass fiber-reinforced materials. Through a systematic characterization of the recyclate, requirements of the filler for the liquid deposition modeling process were identified. Printability and material surface quality of different formulations were analyzed using a low-cost modified 3D printer. Two hypothetical design concepts were also manufactured to validate the field of application. Furthermore, an understanding of the mechanical behavior was accomplished by means of tensile tests, and the results were compared with a benchmark formulation with virgin glass fibers. Mechanically recycled glass fibers show the capability to substitute pristine fillers, unlocking their use for new fields of application.

scholarly journals Smart Build-Plate for Metal Additive Manufacturing Processes

Sensors ◽  
2020 ◽  
Vol 20 (2) ◽  
pp. 360 ◽  
Author(s):  
Adam Hehr ◽  
Mark Norfolk ◽  
Dan Kominsky ◽  
Andrew Boulanger ◽  
Matthew Davis ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Fiber Optic ◽  
Defect Formation ◽  
High Definition ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Ultrasonic Additive Manufacturing ◽  
Fiber Optic Sensing ◽  
Manufacturing Technologies ◽  
Metal Additive

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.

scholarly journals Fatigue Behavior of Metallic Components Obtained by Topology Optimization for Additive Manufacturing

2020 ◽  
Vol 15 (55) ◽  
pp. 119-135
Author(s):  
Felipe Fiorentin ◽  
Bernardo Oliveira ◽  
João Pereira ◽  
José Correia ◽  
Abilio M.P. de Jesus ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Manufacturing Process ◽  
Fatigue Behavior ◽  
Volume Ratio ◽  
Design Solution ◽  
Component Design ◽  
Final Design ◽  
Smoothing Process

The main goal of the present research is to propose an integrated methodology to address the fatigue performance of topology optimized components, produced by additive manufacturing. The main steps of the component design will be presented, specially the methods and parameters applied to the topology optimization and the post-smoothing process. The SIMP method was applied in order to obtain a lighter component and a suitable stiffness for the desired application. In addition, since residual stresses are intrinsic to every metallic additive manufacturing process, the influence of those stresses will be also analyzed. The Laser Powder Bed Fusion was numerically simulated aiming at evaluating the residual stresses the workpiece during the manufacturing process and to investigate how they could influence the fatigue behavior of the optimized component. The effect of the built orientation of the workpiece on the residual stresses at some selected potential critical points are evaluated. The final design solution presented a stiffness/volume ratio nearly 6 times higher when compared to the initial geometry. By choosing the built orientation, it is possible impact favorably in the fatigue life of the component.

scholarly journals On the use of fiber optic sensors embedded in fiber reinforced polymers

2021 ◽  
Author(s):  
Lesha Kolubinski
Keyword(s):  
Fiber Optic ◽  
Fatigue Loading ◽  
Fiber Optic Sensors ◽  
Fiber Reinforced Polymers ◽  
Mechanical Resistance ◽  
Fabrication Method ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Frp Composite ◽  
Reinforced Polymer

Smart structures and structural health monitoring are advancing fields that have potential to yield many benefits to many industries and applications. It is important for applicable sensing technologies to mature so that they may be relied upon. Fiber optic sensors are one such sensing method. Their use in fiber reinforced polymer, FRP, composite materials is reviewed and examined, specifically embedded fiber optic sensors. A fabrication method for embedding fiber Bragg grating, FBG, fiber optic sensors in FRP specimens was developed. This fabrication method is then validated through mechanical testing. Initial specimen stiffness's were determined and the results form the FBGs compared well with mechanical resistance strain gauges. The FBG sensors were also successful in detecting drops in stiffness of the specimens when subjected to fatigue loading.

scholarly journals Applications of Fiber-Reinforced Polymers in Additive Manufacturing

Procedia CIRP ◽  
2017 ◽  
Vol 66 ◽  
pp. 312-316 ◽  
Author(s):  
Thomas Hofstätter ◽  
David B. Pedersen ◽  
Guido Tosello ◽  
Hans N. Hansen
Keyword(s):  
Additive Manufacturing ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Reinforced Polymers
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