Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
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
Page 8
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
Page 9
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
Page 10
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
Page 11
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
Page 12
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)
Page 14
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
Page 15
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
J. Huang, et al., Optics Express, 2014.
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
LASER-BASED MANUFACTURING LABORATORY
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.
LASER-BASED MANUFACTURING LABORATORY
As-Fabricated Samples31
LASER-BASED MANUFACTURING LABORATORY
(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-BASED MANUFACTURING LABORATORY
Laser Surface Polishing - ModelingSimulation of the thermal and melt flow processes of laser polishing for a hemisphericalbump on a flat substrate.
33
LASER-BASED MANUFACTURING LABORATORY
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
LASER-BASED MANUFACTURING LABORATORY
Sensor-Embedded Parts Fabrication35
3D models for sensor embedding. Sensors are embedded in the parts.Curved sensors to be embedded in the printing process.
LASER-BASED MANUFACTURING LABORATORY
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
Page 38
39
Fs laser micromachined structures
Fs laser inscribed FBGs
Page 40
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
Page 41
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
Page 42
Fiber core
Fiber cladding
L1 L2
Stress region
Polarization mode long period fiber grating
25dB extinction ratio
J. Huang, et al., Optics Express, 2014.
Diaphragm based ultrasonic sensor
Page 43
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