additive manufacturing of smart parts with embedded ... · 2 2.5 3 x 10-3 d e f l e c t i o n ( m...

Additive Manufacturing of Smart Parts with Embedded Sensors for In-Situ Monitoring in

Advanced Energy SystemsDE-FE0012272

Investigators: Hai-Lung Tsai (PI), Ming Leu, Missouri S&THai Xiao, Clemson UniversityJunhang Dong, University of Cincinnati

Program Manager: Richard Dunst, NETL

NETL Crosscutting Technology Research Review Meeting, Pittsburgh, PA, April 19, 2016

Outline

• Introduction

• Technical Progresses

• Summary of Research Accomplishments

• Future Work

Demands

• Sensors and instrumentation are needed in advanced energy systems for – Advanced process control/optimization– Health status monitoring of key components– System maintenance and lifecycle management

• Sensors need to survive and operate in the high-T, high-P and corrosive/erosive harsh environments for a long time

Status

• Traditionally, sensors are attached to or installed onto the component after the structure is fabricated

• Costly and complicated sensor packaging are required before installation

• Poor survivability and reliability of the sensors

• Discrepancy between the sensor reading and the actual status

• Potential performance compromise of the host materials/structures

Opportunities

• Smart parts – widely used and proven successful in civil engineering for structural health monitoring (SHM)

• Provide the real-time information of the component and system

• Reduce the complexity in sensor packaging and installation

• Increase the robustness and reliability of the system

Objectives• Main Objective: Demonstrate the new concept of sensor-

integrated “smart part” achieved by additive manufacturing and embedding microwave-photonic sensors into critical components used in advanced energy systems

• Specific objectives– Robust, distributed and embeddable microwave photonic sensors – Additive manufacturing techniques for rapid fabrication of “smart

parts” and sensors embedment– Multifunctional transition layer between the embedded sensor and

host material for sensor protection and performance enhancement– Models to correlate the sensor readings with the parameters of

interest– Sensor instrumentation for in situ and distributed measurement– Feasibility tests and performance evaluation

Project Elements/Overview

• Performers: Missouri S&T, Clemson, University of Cincinnati– Three-year project started on Oct. 1, 2013

• Interdisciplinary team – Hai-Lung Tsai (PI), Professor of Mechanical Engineering, Missouri S&T,

Modeling and AM of metal parts– Ming Leu, Professor of Mechanical Engineering, Missouri S&T, AM of

ceramic parts– Hai Xiao, Professor of Electrical Engineering, Clemson University, Sensors

and Instrumentation, test and evaluation– Junhang Dong, Professor of Chemical Engineering, University of Cincinnati,

Sensor protections

• Success criteria: – Demonstrate concept and capability in simulated laboratory environments

Development of robust, distributed and embeddable sensors and

instrumentation

Approach: Fully distributed microwave photonic fused silica and sapphire fiber sensors

Hai XiaoClemson University

Microwave-Photonics Sensors

• Optical carrier based microwave interferometry (OCMI)– Read optical interferometers using microwave– Optics as the carrier to perform measurement– Microwave as the signal to locate the sensors

Microwave term

Optical term

max

min

2 2 2 2 1 2 1 21 2

2 1 2 1 2

22 2 cos cos2 2

2 1 cos 1 cos cos

O O O O

O O O O

L L W L LE E E A A M tc c

W L W L L LA M t M t dc c c

ω

ω

ω ω

− + + = + = + Ω Ω +

+ + − + + Ω + + Ω + ⋅

J. Huang, et al., Optics Express, 2014.

OCMI Concept

Path 1

Path 2

Control

Intensity Modulator

Optical broadband source

Δλ

High-speed optical detection and amplificationFrequency

scanning

Sync

Optical interferometer

Microwave source Vector microwave detector

Data acquisition

(c) Propagation delay

+

Fourier transform OPD

2 1 22 cos2

O OL LA Mc

− Ω 1 22

2O OW L Lc

+ + Ω

(a) Amplitude spectrum (b) Phase spectrum W+LO1 W+LO2

High speed Photodetector

Measurement Location

MMF: Low Multimodal Influences

0 500 1000 1500 2000 2500 3000 3500-90

-80

-70

-60

-50

Am

plitu

de (d

B)

Frequency (MHz)

R13dB couplerInput

Output

Path 2

Path 1

R2

12.6 cm

MMF

• Michelson interferometer using multimode fibers (fused silica core of 200µm in diameter, 220µm cladding)

• Excellent fringe visibility• No observable multimodal influences

L. Hua., Applied Optics, 2015

Strain at 600ºC, 200µm Fiber

0 100 200 300 400 500 600 700

-1.6

-1.4

-1.2

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

Increasing steps Linear fit

Spec

tral s

hift

(MH

z)Strain (με)

Slope: 2.37 KHz/με

1740 1742 1744 1746 1748

-80-75-70-65-60-55-50-45-40-35-30

1000 1100 1200 1300 1400 1500

-70

-60

-50

-40

-30

Am

plitu

de (

dB)

Frequency (MHz)

Am

plitu

de (d

B)

Frequency (MHz)

0 με 100 με 200 με 300 με 400 με 500 με 600 με 700 με

• High sensitivity for strain sensing (∼10με) at 600ºC• Small temperature cross sensitivity

L. Hua., Applied Optics, 2015

Quartz rod (800μm dia. Uncladded)

Fused silica rod 800μm dia.

High temperature response

R13dB coupler

Input

Output

Path 2

Path 1

R2

18.7 cm

Large core fiber

Interference fringes

Quartz rod can be used to measure strains at high temperaturesL. Hua., Applied Optics, 2015

Sapphire Michelson Sensor (125 µm)

1000 1500 2000 2500 3000 3500 4000 4500

-60

-50

-40

-30

Am

plitu

de (d

B)

Frequency (MHz)

Joint by fusion

R1

3dB multimode fiber coupler

Input

Output

Joint by fusion

R2

10.2 cm

Silica graded-index multimode (62.5 μm core and 125 μm cladding)

Single crystal sapphire fiber (125 μm diameter, uncladded)

Excellent fringe visibility > 30dBSapphire fiber Michelson OCMI

J. Huang, et al., IEEE Photonics Technology Letters, 2015.

0 200 400 600 800 1000 1200 1400 1600

4220

4240

4260

4280

4300

4320

Increasing Decreasing

Res

onan

t fre

quen

cy (M

Hz)

Temperature (°C)

Slope ≈ -0.064 MHz/°C

Fully distributed sensing

• Spatially continuous (no dark zone), fully distributed sensing.

• High spatial resolution (<1cm)

• High sensitivity (∼με)

• Flexible gauge length (1cm –100m)

• Long reaching distance (∼km)

• Can be implemented using various fibers including sapphire and quartz rods

0 30 60 90 120 0

10

20

0

0.5

1

1.5

2

2.5

3

x 10-3

Deflection (mm)

Axial location (cm)

stra

in

Measurement data

Axia

l str

ain

(e)

Push

IFPI 1 IFPI 5 IFPI 2 IFPI 4 IFPI 8 IFPI 3 IFPI 6 IFPI 7 IFPI 9

L

Cascaded OCMI-IFPI sensor epoxied on the beam

Aluminum cantilever beam


Develop a multifunctional transition layer between the embedded sensor

and the host material for sensor protection

Sapphire fiber/rodDense claddingSintered porous layer of cladding material

Dense metal layer(Porous) ceramic adhesion

Refractory block

Approach: Design and select ceramic and metal materials based on structural and chemical potteries

Junhang Dong, University of Cincinnati

Interface Thermochemical Stability in the Layered Structure for Sensor Protection/Installation

Solid-Solid Connections: MgAl2O4 / Silicalite/Stainless-steel three-layer structure

Interface Stability: Stable at 750oC; stability at higher temperature is yet to be tested

Silicalite surface

MgAl2O4surface

Spinal MgAl2O4

Silicalite

Stainless steel

Multilayer-Protected FOS Fabrication

Structure: (Zirconia)/(α-alumina)/(silica optical fiber)

Fabrication: inserting optical fiber into zirconia small tube by alumina adhesives

Stability: Fiber strongly attached to structure after thermal cycles; tested stability at 750oC

Zirconia tube

α-aluminafilling

Opticalfiber

Zirconia

Alumina

Optical Fiber alumina

Long-Term Stability of Sapphire Protection

• The structures of silicalite-coated-sapphire is stable after firing at 1000oC for 200 h according to SEM and EDS examinations – No structural damage or elemental diffusion across the Silicalite/Sapphire interface was found.

Polycrystalline silicalite

Sapphire chip

Long-Term Stability of Sapphire Multilayer Protection

The structures of silicalite-coated-sapphire with an overcoats of ZAlMg (ZrO2-Al2O3-MgO mixture) and ADZ (Zr1-0.75xAlxSiO4) are both stable after firing at 1000oC for 200 h according to SEM and EDS examinations –No structural damage or inter-layer element diffusion was found.

Silicalite

Sapphire

AZlMg

Silicalite

Sapphire

ADZ

Additive Manufacturing of Liner Blocks (Ceramic) with Embedded

Sensors

Approach: Multi-extruder freeze-form extrusion based additive manufacturing

Ming LeuMissouri University of Science and Technology

Novel AM Process

22

o A layer is deposited through a moving nozzle.o Oil is pumped to surround the layer.o Infrared lamp is used to partially dry the layer.o Next layer is deposited.

Tool-path Planning Software

23

o An algorithm has been developed and coded into computer software too Read the geometry of the part in STL format.o Slice the part.o Generate tool-path for each layer.o Generate a G&M code for output to a manufacturing machine for part fabrication by 3D printing.

Example Printed Parts

24

Mechanical Properties Measured

25

o Relative density (Archimedes’): 98%o Flexural strength (ASTM C1161 four-point bend): 364±50 MPao Young’s modulus: 390±21 GPao Fracture toughness (ASTM C1412 chevron-notched beam, configuration A): 4.5±0.1 MPa.m0.5o Hardness (ASTM C1327 Vickers indentation test): 19.8±0.6 GPa

Microstructure Evaluation

26

o Microstructure was observed under SEMo Grains are highly packedo Average grain sizebased on lineal intercept: 2.1 μm

o Sapphire fibers of 75, 125 and 250 μm diameter were successfully embedded in the aluminum partso A signal was passed through the fibers to ensure that the embedded fibers are not damaged

Fiber Embedment

o Micrographs of the embedded fibers show good mechanical bonding between fiber and partFiber Embedment

Sapphire fiber

Alumina part

LASER-BASED MANUFACTURING LABORATORY

Additive Manufacturing of Pipe (Metal) with Embedded Sensors

Approach: Foil-Based Dual-Laser Additive Manufacturing Technology

Hai-Lung TsaiMissouri University of Science and Technology


30

UV laser cuttinghead

Fiber laser scan head

Foil rollerFoil bed

X-Y stage

gas

Computer

Motion stage control

Fiber laser

Heater

Foil-Based AM System Setup• System Design, Hardware and Software Implementations, and Integration.


As-Fabricated Samples31


(a) Surface morphology of the raster-scan weld;

(b) Cross-section of a single-line laser foil-welding onto a substrate;

(c) Cross-section of the raster-scan weld of one-layer foil onto a substrate;

(d) Cross-section of a multi-layer raster-scan weld

Laser Welding 32


Laser Surface Polishing - ModelingSimulation of the thermal and melt flow processes of laser polishing for a hemisphericalbump on a flat substrate.

33


Laser Surface Polishing - ExperimentThe surface roughness can be significantly reduced from about 20 µm to less than 3 µm

Top surface of laser polishing Cross-section of laser polishing

Initial surface

Polished surface

Cross-section line

Initialsurface

Polishedsurface

34


Sensor-Embedded Parts Fabrication35

3D models for sensor embedding. Sensors are embedded in the parts.Curved sensors to be embedded in the printing process.


Thermal Stress-Strain Modeling of Embedded Sensors

Pressure CausedStress-Strain Distribution

(a) (b)

(c) (d)

Temperature CausedStress-Strain Distribution

36

IIM system under construction

37

Helical structure inside fiber

39

Fs laser micromachined structures

Fs laser inscribed FBGs

5 μmGrating

Core ~ 9 μm

0.3 nm drift for 20 days in 800°C

Fiber inline waveplate

• The polarization status can be flexibly changed by fs laser induced stress patterns inside the fiber

• Waveplates of any desired phase retardance can be fabricated in a SMF

Referencepoint

No.0

No.4

No.8

No.14

No.16

WD

H

x

y

Fiber core

Fiber cladding Fs laser ablated region

L1 L2

L. Yuan, et al., Optics Express, 2016.

Fiber inline polarizer

• Fs laser inscribed periodic stress patterns near the core of a single mode fiber

• Polarization dependent core-cladding mode coupling result in an inline polarizer

• Fiber polarizers can be fabricated anywhere we want

Fiber core

Fiber cladding

L1 L2

Stress region

Polarization mode long period fiber grating

25dB extinction ratio


Diaphragm based ultrasonic sensor

Pop Candy

Spiral

• Endface diaphragm based acoustic sensor

0

0.02

0.04

0.06

0.08

0.1

0.12

1.20E-05 1.30E-05 1.40E-05 1.50E-05 1.60E-05

Volta

ge (V

)

Time (s)

Cantilevers

Summary of Progresses

Microwave photonic sensors and instrumentation have been developed and proven effective

Protective coating materials have been identified and successfully coated on silica and sapphire

Additive Manufacturing techniques have been developed for fabrication of smart partsMulti-extruder freeze-form extrusion for ceramic parts

Foil-Based Dual-Laser Additive Manufacturing for metals

Information integrative smart manufacturing system

Models have been developed to study the induced stress/strain on the sensor caused by external high pressures or high temperatures

Future Work

• Continue optimization and improvement on– Sensors: stability, loss sensitivity, temperature cross sensitivity,

protection, embedment– Additive manufacturing techniques and processes

• Ceramic: sintering, new materials, functionally gradient, mechanical tests• Metal: surface improvement, 3D metal parts

– Modeling: temperature and pressure coupled models– Protective coating: multilayer structure and coating on real sensors

• Test embedded sensors in smart parts

• Making sensors while making the parts

• Initial tests of sensors embedded in the smart parts

additive manufacturing of smart parts with embedded ... · 2 2.5 3 x 10-3 d e f l e c t i o n ( m...

Documents