Rapid advances in 3D printing enable the construction of complex metal structures. However, sensor embedding within 3D printed metal structures has been challenging due to its extremely high-temperature condition. Here, we embedded an optical fibre sensor for temperature monitoring within a Ni-alloy miniature turbine blade by directed energy deposition (DED) printing. To endure the high-temperature condition, a fibre Bragg grating (FBG) sensor was electroplated with a Ni layer, and various 3D printing parameters were optimised. In particular, to minimise the accumulation of thermal energy in the FBG sensor, ‘line-by-line printing and stop’ process was applied around the sensor. The embedded sensor accurately measured temperature cycling up to 500°C with the sensitivities of 28.3 and 27.2 pm/K in heating and cooling cycles, respectively. Finally, an FBG sensor was successfully embedded in a miniature turbine blade by our DED process, demonstrating its feasibility for high-temperature monitoring.
Bibliographical noteFunding Information:
This work was supported by Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korea government (MOTIE) (grant number 20193310100030, Development of high efficient F-class gas turbine hot component by controlling and applying Design for Additive Manufacturing), and the Human Resources Development Program (grant number 20204030200110), and also supported by the Korea Institute of Industrial Technology as ?Development of intelligent root technology with add-on modules (kitech EO-21-0009)?. S. I. Kim and H. Y. Jung thank the GeoRyu fellowship generously provided by Dr. Jong Bong Kim.
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All Science Journal Classification (ASJC) codes
- Signal Processing
- Modelling and Simulation
- Computer Graphics and Computer-Aided Design
- Industrial and Manufacturing Engineering