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Printed Structural Temperature Monitoring Embedded in Multi-Process Hybrid Additive Manufacturing

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Abstract

A printed and built-in geometry with a capability of detecting temperatures over a wide range are highly sought-after characteristics for a structural health monitoring temperature sensor. In this work, we describe a printable copper-graphene electronic sensor for temperature monitoring with real-time deployment into a printed metal structural component. The smart component is manufactured using a combination of three additive processes: a direct-ink writing, laser powder bed fusion (LPBF), and ultrasonic additive manufacturing (UAM). The sensor is printed on a flexible ceramic substrate, embedded in the stainless steel LPBF component and capped with a UAM aluminum layer. The sensor exhibits a high resistance temperature sensitivity in a wide temperature detection range, with the performance capping at 500°C. These results, and the demonstrated ability to read temperature wirelessly, provide a path for remote structural health monitoring applications for additively manufactured components.

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Acknowledgments

Financial support at University at Buffalo (S.R.) was provided by the U.S. Army Research Laboratory under Award W911NF-20-2-0016. We would also like to thank Yash Bandari for help coordinating the efforts. Financial support at EWI was provided by the U.S. Army Research Laboratory under Cooperative Agreement W911NF-13-2-0038 (Modification P00011).

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, Research and Education in Energy Environment and Water Institute, University at Buffalo, The State University of New York, Buffalo, New York, 14260, USA

    Saurabh Khuje, Zheng Li & Shenqiang Ren

  2. Fabrisonic LLC, Columbus, OH, 43221, USA

    Adam Hehr

  3. EWI, Columbus, OH, 43221, USA

    Ajay Krishnan

  4. Buffalo Manufacturing Works operated by EWI, Buffalo, NY, 14211, USA

    Lee Kerwin & Alex Kitt

  5. Army Research Laboratory, Aberdeen Proving Ground, Maryland, 21005, USA

    Jian Yu

  6. Department of Chemistry, University at Buffalo, The State University of New York, Buffalo, New York, 14260, USA

    Shenqiang Ren

  7. Research and Education in Energy Environment and Water Institute, University at Buffalo, The State University of New York, Buffalo, New York, 14260, USA

    Shenqiang Ren

Authors
  1. Saurabh Khuje
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  2. Adam Hehr
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  3. Zheng Li
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  4. Ajay Krishnan
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  5. Lee Kerwin
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  6. Alex Kitt
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  7. Jian Yu
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  8. Shenqiang Ren
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Contributions

The manuscript was written through contributions of all authors. A. K., J. Y., S. R designed and supervised the project. S. K. and Z. L worked on the synthesis of printable Cu nanostructured ink and sensor preparation. A. H., A. K., L. K., A. K., carried out the metal additive manufacturing and measurements. All authors have given approval to the final version of the manuscript.

Corresponding author

Correspondence to Shenqiang Ren.

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This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Additive Manufacturing. The issue was organized by Dr. William Frazier, Pilgrim Consulting, LLC; Mr. Rick Russell, NASA; Dr. Yan Lu, NIST; Dr. Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock.

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Khuje, S., Hehr, A., Li, Z. et al. Printed Structural Temperature Monitoring Embedded in Multi-Process Hybrid Additive Manufacturing. J. of Materi Eng and Perform 30, 5093–5099 (2021). https://doi.org/10.1007/s11665-021-05658-8

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  • DOI: https://doi.org/10.1007/s11665-021-05658-8

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