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Fiber Optic Sensor Fused Additive Manufacturing

Zou, Ran (2021) Fiber Optic Sensor Fused Additive Manufacturing. Doctoral Dissertation, University of Pittsburgh. (Unpublished)

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This dissertation research establishes the foundation for converging disciplines to fiber optic sensors and additive manufacturing for smart part fabrication for energy system applications. Through innovation in numerical designs, thorough studies of layer-by-layer additive manufacturing procedures, and innovation in high-temperature fiber optic sensor development, this dissertation presents fiber optic sensor embedding in metals for smart component manufacturing.

In this dissertation, standard telecom-grade single-mode optical fibers were metalized by nickel sulfamate electroplating method. Through electroplating process optimization, residual strain of fiber coating induced on optical fiber were controlled to ensure metal integrity of fiber sensors. Using Laser Engineered Net Shaping (LENS) process, metalized fiber sensors were embedded into objects with flat surfaces and curved surfaces to fabricate smart components. Using Rayleigh optical frequency domain reflectometry technology, the embedded fiber optic sensors were used to perform accurate and distributed temperature and strain sensing with 5 mm spatial resolution. Finite element analyses were performed to study additive manufacturing process. Plastic and elastic residual strain distributed incurred by the process were calculated and compared with measurement results obtained by embedded sensors. Both temperature and strain measured by fiber sensors are in excellent agreement with numerical simulations. Using embedded fiber sensor measurement results are cue, various laser processes were applied to further temper properties of metal components. This dissertation explores potentials on using adaptive optical technology to perform rapid and high precision laser shock peening to mitigate residual strain induced by additive manufacturing. Using embedded fiber sensors, laser shock peening induced strain modifications were measured with high spatial resolution to improve properties and accuracy of 3D manufactured metal components against corrosion.

Research discussed in this dissertation has advanced both fiber optic sensing technology and additive manufacturing. By incorporating advanced optical sensing technology directly into the component’s design and additive manufacturing processes, this research results in new manufacturing techniques to produce a wide array of smart parts for advanced energy systems. The seamless incorporation of multi-functional fiber optic devices into components and parts common to advanced energy system will enable and facilitate condition-based monitoring of key components and systems of fossil, renewable and nuclear power systems to improve safety and efficiency of fossil-fuel energy power generation.


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Item Type: University of Pittsburgh ETD
Status: Unpublished
CreatorsEmailPitt UsernameORCID
Zou, Ranraz26@pitt.eduraz26
ETD Committee:
TitleMemberEmail AddressPitt UsernameORCID
Committee ChairChen, Pengpec9@pitt.edupec9
Committee MemberYun, Minheemiy16@pitt.edumiy16
Committee MemberChen, JunJUC48@pitt.eduJUC48
Committee MemberMao, Zhi-Hongzhm4@pitt.eduzhm4
Committee MemberTan, Sushengsut6@pitt.edusut6
Committee MemberOhodnicki, PaulPRO8@pitt.eduPRO8
Date: 26 January 2021
Date Type: Publication
Defense Date: 4 May 2020
Approval Date: 26 January 2021
Submission Date: 25 October 2020
Access Restriction: No restriction; Release the ETD for access worldwide immediately.
Number of Pages: 124
Institution: University of Pittsburgh
Schools and Programs: Swanson School of Engineering > Electrical and Computer Engineering
Degree: PhD - Doctor of Philosophy
Thesis Type: Doctoral Dissertation
Refereed: Yes
Uncontrolled Keywords: embedded optical fiber sensor, additive manufacturing, laser shock micro forming, laser shock peening.
Date Deposited: 26 Jan 2021 17:11
Last Modified: 26 Jan 2021 17:11


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