Embedding eddy current sensors into LPBF components for structural health monitoring

Laser powder bed fusion (LPBF) facilitates the integration of external elements like sensors into workpieces during manufacturing. These embedded components enable e.g. part monitoring, thus being a fundamental application of industry 4.0. This study assesses the feasibility of embedding eddy current (EC) sensors for non-destructive testing (NDT) into SLM components aiming at structural health monitoring (SHM). A reliable embedding process for EC sensors is developed, ensuring the survivability of the sensors for the LPBF process and its harsh conditions. The experiments conducted demonstrate the possibility to use the embedded EC sensor to observe and detect a controlled crack growth. The cracks are realized either with direct EDM cutting or on the course of a fatigue test of CT specimens. The data retrieved by the embedded EC sensors are proven to provide a direct information about the severity of a damage and its evolution over time for both approaches. Thus, supporting the validation of such an innovative and promising SHM concept.

Automated summary

This study assesses the feasibility of embedding eddy current (EC) sensors for non-destructive testing (NDT) into SLM components for structural health monitoring (SHM). A reliable embedding process for EC sensors is developed, showcasing the effectiveness of the sensors in LPBF process. Experimental results demonstrate that the embedded EC sensors can be used to observe and detect controlled crack growth, providing direct information about damage severity and evolution.