Smart Build-Plate for Metal Additive Manufacturing Processes.

Area of Science:

• Materials Science
• Manufacturing Engineering
• Sensors and Instrumentation

Background:

• Metal additive manufacturing (MAM) processes generate significant residual stress and temperature gradients.
• Monitoring build-plate conditions is crucial for ensuring part quality and preventing defects.
• Existing monitoring methods often lack the spatial resolution or real-time feedback needed for complex MAM parts.

Purpose of the Study:

• To develop and evaluate a smart build-plate for real-time monitoring of metal additive manufacturing processes.
• To integrate high-definition fiber optic sensing into a build-plate for measuring strain, temperature, and residual stress.
• To assess the tool's capability in identifying defect formation and growth, such as delamination and cracks.

Main Methods:

• Manufactured an aluminum alloy 6061 build-plate using ultrasonic additive manufacturing (UAM) to embed fiber optic sensing fiber.
• Utilized laser-powder bed fusion (L-PBF) to print AlSi10Mg geometries onto the smart build-plate.
• Employed the embedded fiber optic sensors to measure strain states, inferring temperature and residual stress during L-PBF printing.

Main Results:

• Successfully embedded fiber optic sensing fiber within the UAM-manufactured build-plate without damage.
• The smart build-plate accurately detected heat generation during the L-PBF process.
• The system identified the onset and growth of delamination in the printed parts near the build-plate surface.

Conclusions:

• The developed smart build-plate is a viable tool for real-time monitoring in metal additive manufacturing.
• Embedded fiber optic sensing enables effective tracking of thermal conditions and defect evolution.
• This technology enhances quality control and defect detection capabilities in MAM.