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Open AccessArticle

Smart Build-Plate for Metal Additive Manufacturing Processes

1
Fabrisonic LLC, Columbus, OH 43221, USA
2
Luna Innovations Inc., Blacksburg, VA 24060, USA
3
Edison Welding Institute (EWI), Columbus, OH 43221, USA
*
Author to whom correspondence should be addressed.
Sensors 2020, 20(2), 360; https://doi.org/10.3390/s20020360
Received: 6 December 2019 / Revised: 3 January 2020 / Accepted: 5 January 2020 / Published: 8 January 2020
(This article belongs to the Special Issue Optical Fibers for Distributed Sensors)
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. View Full-Text
Keywords: additive manufacturing; fiber optic; HD-FOS; UAM; L-PBF; embedded sensing additive manufacturing; fiber optic; HD-FOS; UAM; L-PBF; embedded sensing
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Hehr, A.; Norfolk, M.; Kominsky, D.; Boulanger, A.; Davis, M.; Boulware, P. Smart Build-Plate for Metal Additive Manufacturing Processes. Sensors 2020, 20, 360.

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