Ti- 6Al- 4V ( PZT/LiNbO3 )

( Al2 O3 Past e)

Investigation on Smart Parts with EmbeddedPiezoelectric Sensors via Additive Manufacturing

Gonzalez, J.A., Hossain, M.S., Martinez, R., Rodriguez, G., Shuvo, M.A.I.,Gaytan, S. 1,3, Wicker, R.,1,3 Choudhuri, A.,1 Lin, Y.1,†

1 Department of Mechanical Engineering, The University of Texas at El Paso2 Department of Metallurgy and Materials Engineering, The University of Texas at El Paso

3 W.M. Keck Center for 3D Innovation, The University of Texas at El Paso

Fabrication and CharacterizationObjective• To design, fabricate, and test “smart parts” with embedded sensors.

Figure 2: Potentia l appl ic ations for the “s mart parts ”.Figure 1: Motiv ation behind th is pro jec t.

EBM Manufacturing Process

Results

Future WorkMethodology & Materials

Figure 3: (a) Arc am A2X Elec tron Beam Mel ting mac hine. (b) Sc hematic o f EBM mac hine. (c ) Addi tiv e manufac turing proc es s .

(b) (c)(a)

Introduction

Piezo Sensing Mechanism

Figure 4: Piez oelec tric e ffec t, us ed to s ens e stra in , v ibration, and pres s ure. (a) no v o l tage, thus no induc ed s tra in or v ic e-v ers a. (b)

Vol tage/Tens i le s tra in re la tion. (c ) Vol tage/Compres s iv e s tra in re la tion.

Figure 5: Model o f a PZT driv en dy namic s truc tura l s y s tem.

Smart Part fabrication

Figure 6: “Stop and go” proc es s for s mart part fabric ation. (a) Partia lpart wi th poc k et for the s ens or. (b) Sens or has been e mbedded intothe poc k et, and nonc onduc tiv e adhesiv e has been appl ied. (c)Complete fabric ation of the s mart part wi th a l l the in ternalc omponents c omplete ly enhous ed and protec ted. (d) Cros s -s ec tions c hematic v iew of the s mart part.

Simulation

Figure 14: 3D simulation of piezoelectric ceramic and alumina coating (right), Results of temperature distribution (left) and von misses stress (middle).

Input

c ondi tionsABAQUS

analy s is

Output: Data for

c a l ibration

Temperature and pressure conditions

Elastic regime

Coupled thermal -mechanical -

e lectrical response.

Electrical response of piez oelectric

Figure 13: Conceptual design of the simulation task.

High-Temperature Wiring

Wiring Mater ial Melting Point Electr ical Resistivity (at 20 °C) Elongation at BreakPlatinum 1768.3 °C 105 nΩ·m 35%

Titanium 1668 °C 420 nΩ·m 54%

Copper 1084.62 °C 16.78 nΩ·m 60%

Table 1: The chosen wiring elements, Platinum and Titanium properties, are compared to Copper.

Figure 15: Samples fo r,tens i le tes t (top), fa tigue test(middle), three point bendingtes t (bottom). (a) Tes t s amplewi thout poc k et or s ens or, (b)wi th poc k et for the s ens or, (c)wi th embedded s ens or in thepoc k et.

Figure 11: Metallographic images for top and bottom

section of Ti-6Al-4V.

Figure 10: Cylindrical EBM samples for material

characterization.

Figure 12: Additive Manufacturing enabled Energy Parts, (a) Pre-mixer (LSL), (b) Pre-mixer

(EBM), (c) Swirler, and (d) Fuel Injector .

• The authors acknowledge thefinancial support for this workby the DOE – NETL. AwardNumber: DE-FE0012321.

Figure 7: Sc hematic for “ S mart Pre mix er” wi th e mbedded s ens or.(a) heat s h ie lds . (b) Sc he matic of Pre mix er’s loc ation in Turb ine.(c ) Addi tiv e manufac tured Premix er wi th poc k et. (d) Sma rtPremix er wi th embedded s ens or.

Sensor Pocket

Em beddedSensor

Figure 8: Sc hematic o f “s top and go” proc es s during addi tiv e manufac turing.

Acknowledgements

Students Involvement

• Perform mechanical testing.• Evaluate the bonding strength of alumina paste as bonding agent.• Assessment of sensing parameters before and after fabrication.

Mechanical Testing

(a)

(b)

(c) (d)

(a) (b)

(c) (d)

Figure 9: Fabric ated “Smart Parts ”, (a) p iez oc eramics ens or and ins ert part, (b) bottom part pres s fi tted in

the mas t p la te, and (c ) fabric ated “s mart part”.