Shape Deposition Manufacturing of smart metallic structures with embedded sensors

The need to obtain information on the performance and lifetime of a tool in service is of prime importance to many industries. It calls for on-line acquisition of information such as temperature and strain values from tools and structures. With embedded sensors, structures are capable of monitoring parameters at critical locations not accessible to ordinary sensors. To embed sensors in the functional structures, especially metallic structures, Shape Deposition Manufacturing (SDM) is a methodology capable of integrating sensors during the production of tooling or structural components. Thin film sensors and fiber optic sensors have been identified as two promising candidates to be integrated in metallic structures. Embedded thin film strain gages have been characterized in a four-point bending test and the results, showing linearity and no hysteresis, match with those from the theoretical model and commercially available strain gages. Fiber optic sensors have been successfully embedded in nickel and stainless steel structures. The embedded fiber optic sensors have been used to measure temperatures and strains. They provide higher sensitivity, good accuracy, and high temperature capacity. Based on fiber optic sensor embedding techniques, a remote temperature/strain sensing system suitable rotating objects, such as turbine blades, has been developed. The developed techniques can be harnessed for rapid prototyping of smart metallic structures.