Integrating Fiber Optic Strain Sensors into Metal Using Ultrasonic Additive Manufacturing

Ultrasonic Additive Manufacturing (UAM), a rather new three-dimensional (3D) printing technology, uses ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. This low temperature attribute of the process enables integration of temperature sensitive components, such as fiber optic strain sensors, directly into metal structures. This may be an enabling technology for Digital Twin applications, i.e., virtual model interaction and feedback with live load data. This study evaluates the consolidation quality, interface robustness, and load sensing limits of commercially available fiber optic strain sensors embedded into aluminum alloy (AA) 6061. Lastly, an outlook on the technology and its applications is described.