PSI - Issue 34

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.com Science irect Structural Integrity Procedia 00 (2019) 000 – 000

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Procedia Structural Integrity 34 (2021) 32–38

The second European Conference on the Structural Integrity of Additively Manufactured Materials Production Assessment of Hybrid Directed Energy Deposition Manufactured Sample with Integrated Effective Structural Health Monitoring channel (eSHM) Zoé Jardon a,b, *, Michaël Hinderdael a , Julien Ertveldt a , Patrick Guillaume a a Dept. Of Mechanical Engineering, Vrije Universiteit Brussel, Pleinlaan, 2, 1050 Elsene, Belgium b Environmental and Applied Fluid Dynamics Department, von Karman Institute for Fluid Dynamics, Chaussée de Waterloo 72, Belgium Abstract Additively manufactured components are questioned for their fatigue performance and therefore not adopted for safety critical applications so far. The components might contain material imperfections and residual stresses due to the high temperature gradients during the printing process. The se stresses alter the component’s structural integrity and are one of the main sources of component deformation and cracking. The effective Structural Health Monitoring system (eSHM), developed and patented by the Vrije Universiteit Brussel, fully exploits the flexibility offered by the 3D printing process by integrating a smart continuous monitoring technology inside additively manufactured parts. The system is based on the detection of pressure changes in 3D-curved internal channels embedded in the fatigue critical regions of the component. The pressure is continuously monitored at the channel extremities by externally mounted pressure sensors. The system is capable of detecting the presence and finding the location of a fatigue crack. This paper proposes an assessment of the production of a fatigue sample with integrated eSHM-system using the MiCLAD in-house hybrid Directed Energy Deposition machine developed by the Additive Manufacturing Research Group of the VUB. It has the particularity to allow the combination of both additive and subtractive milling operations for the production of a part. Different printing strategies are presented and compared in terms of final geometry and internal channel roughness, known to be crucial to avoid undesired fatigue initiation and to obtain an accurate detection and localization of the fatigue crack. The encountered difficulties during the production process are identified and solutions are proposed. © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers Keywords: Structural Health Monitoring; hybrid Directed Energy Deposition; eSHM-system; internal channel; The second European Conference on the Structural Integrity of Additively anufactured Materials Production ssess ent of ybrid irected nergy eposition anufactured Sa ple ith Integrated Effective Structural Health onitoring channel (eS ) Zoé Jardon a,b, *, Michaël Hinderdael a , Julien Ertveldt a , Patrick Guillau e a a Dept. Of Mechanical Engineering, Vrije Universiteit Brussel, Pleinlaan, 2, 1050 Elsene, Belgium b Environmental and Applied Fluid Dynamics Department, von Karman Institute for Fluid Dynamics, Chaussée de Waterloo 72, Belgium Abstract Additively manufactured components are questioned for their fatigue performance and therefore not adopted for safety critical applications so far. The components might contain material imperfections and residual stresses due to the high temperature gradients during the printing process. The se stresses alter the component’s structural integrity and are one of the main sources of component deformation and cracking. The effective Structural Health Monitoring system (eSHM), developed and patented by the Vrije Universiteit Brussel, fully exploits the flexibility offered by the 3D printing process by integrating a smart continuous monitoring technology inside additively manufactured parts. The system is based on the detection of pressure changes in 3D-curved internal channels embedded in the fatigue critical regions of the component. The pressure is continuously monitored at the channel extremities by externally mounted pressure sensors. The system is capable of detecting the presence and finding the location of a fatigue crack. This paper proposes an assessment of the production of a fatigue sample with integrated eSHM-system using the MiCLAD in-house hybrid Directed Energy Deposition machine developed by the Additive Manufacturing Research Group of the VUB. It has the particularity to allow the combination of both additive and subtractive milling operations for the production of a part. Different printing strategies are presented and compared in terms of final geometry and internal channel roughness, known to be crucial to avoid undesired fatigue initiation and to obtain an accurate detection and localization of the fatigue crack. The encountered difficulties during the production process are identified and solutions are proposed. © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers Keywords: Structural Health Monitoring; hybrid Directed Energy Deposition; eSHM-system; internal channel; 2021 The Authors. Published by Elsevier B. . This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers

* Corresponding author. Tel.: +32 2 629 23 24. E-mail address: zoe.jardon@vub.be * Corresponding author. Tel.: +32 2 629 23 24. E-mail address: zoe.jardon@vub.be

2452-3216 © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers 2452-3216 © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers

2452-3216 © 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers 10.1016/j.prostr.2021.12.005