Skip to main content
SpringerLink
Log in

In situ embedment of type K sheathed thermocouples with directed energy deposition

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Advanced nuclear reactor systems require new technologies for heat transfer and system monitoring to achieve autonomous operations and improved performance. Additive manufacturing offers the design flexibility to allow in situ sensor embedment to realize new manufacturing techniques that can improve the smart manufacturing, real-time monitoring, and performance of these systems. This study focuses on experiments investigating the feasibility of in situ sensor embedment using directed energy deposition (DED). We embedded type K thermocouples into 316L stainless steel (SS) samples using two different configurations (e.g., exposed and embedded tips) and two designs, one with the sensor placed directly onto the substrate (e.g., flush to substrate) and the second using an additive manufacturing base. Embedded sensor samples are analyzed via in situ measurements and high-temperature performance validation tests at 350 and 900 ºC. Temperature performance results at both temperatures show good agreement with manufacturer specifications, proving that these sensors could still capture accurate temperature readings after experiencing the high-heat laser processing during DED fabrication. Additional optimization experiments were performed on the exposed tip configuration using a surrogate thermocouple to improve tolerances and the embedment process. These experiments lead to improved tolerances, lower porosity, smaller gaps between the sensor and base, and better junction contact for the sensor. Further optimization of this embedment strategy will improve the structural stability and tolerances within the component. This embedment strategy demonstrates a proof of feasibility for DED embedment with commercial sheathed thermocouples. Further investigations into fabrication strategies should be conducted to fully realize smart manufacturing and an advanced real-time monitoring system.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21

Similar content being viewed by others

References

  1. Kumar A (2018) Methods and materials for smart manufacturing: additive manufacturing, Internet of Things, flexible sensors and soft robotics. Manuf Lett 15:122–125. https://doi.org/10.1016/j.mfglet.2017.12.014

    Article  Google Scholar 

  2. Tomaz I, UíMhurchadha SM, Marques S et al (2021) The development of a smart additively manufactured part with an embedded surface acoustic wave sensor. Addit Manuf Lett 1:100004. https://doi.org/10.1016/j.addlet.2021.100004

    Article  Google Scholar 

  3. Sun C, Wang Y, McMurtrey MD et al (2021) Additive manufacturing for energy: a review. Appl Energy 282:116041. https://doi.org/10.1016/j.apenergy.2020.116041

    Article  Google Scholar 

  4. Jung ID, Lee MS, Lee J et al (2020) Embedding sensors using selective laser melting for self-cognitive metal parts. Addit Manuf 33:101151. https://doi.org/10.1016/j.addma.2020.101151

    Article  Google Scholar 

  5. Zuo X, Zhang W, Chen Y et al (2022) Wire-based directed energy deposition of NiTiTa shape memory alloys: microstructure, phase transformation, electrochemistry, X-ray visibility and mechanical properties. Addit Manuf 59:103115. https://doi.org/10.1016/j.addma.2022.103115

    Article  Google Scholar 

  6. Li S, Li JY, Jiang ZW et al (2022) Controlling the columnar-to-equiaxed transition during directed energy deposition of Inconel 625. Addit Manuf 57:102958. https://doi.org/10.1016/j.addma.2022.102958

    Article  Google Scholar 

  7. Bevans B, Ramalho A, Smoqi Z et al (2023) Monitoring and flaw detection during wire-based directed energy deposition using in-situ acoustic sensing and wavelet graph signal analysis. Mater Des 225:111480. https://doi.org/10.1016/j.matdes.2022.111480

    Article  Google Scholar 

  8. Juhasz M, Tiedemann R, Dumstorff G et al (2020) Hybrid directed energy deposition for fabricating metal structures with embedded sensors. Addit Manuf 35:101397. https://doi.org/10.1016/j.addma.2020.101397

    Article  Google Scholar 

  9. Petrie CM, Schrell AM, Leonard DN et al (2021) Embedded sensors in additively manufactured silicon carbide. J Nucl Mater 552:153012. https://doi.org/10.1016/j.jnucmat.2021.153012

    Article  Google Scholar 

  10. Choi H, Konishi H, Xu H, Li X (2007) Embedding of micro thin film strain sensors in sapphire by diffusion bonding. J Micromechanics Microengineering 17:2248–2252. https://doi.org/10.1088/0960-1317/17/11/011

    Article  Google Scholar 

  11. Hyer HC, Sweeney DC, Petrie CM (2022) Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements. Addit Manuf 52:102681. https://doi.org/10.1016/j.addma.2022.102681

    Article  Google Scholar 

  12. van Rooyen IJ, Sabharwall P (2020) Techniques for incorporating sensors into apparatuses and systems. U.S. Patent Application No. 17/089,922. Filed November 5, 2020. https://patents.justia.com/patent/20210134472

  13. Ren H, Yang X, Wang Z et al (2022) Smart structures with embedded flexible sensors fabricated by fused deposition modeling-based multimaterial 3D printing. Int J Smart Nano Mater 13:447–464. https://doi.org/10.1080/19475411.2022.2095454

    Article  Google Scholar 

  14. Sweeney DC, Schrell AM, Liu Y, Petrie CM (2020) Metal-embedded fiber optic sensor packaging and signal demodulation scheme towards high-frequency dynamic measurements in harsh environments. Sens Actuators Phys 312:112075. https://doi.org/10.1016/j.sna.2020.112075

    Article  Google Scholar 

  15. Ramanathan AK, Gingerich MB, Headings LM, Dapino MJ (2021) Metal structures embedded with piezoelectric PVDF sensors using ultrasonic additive manufacturing. Manuf Lett. https://doi.org/10.1016/j.mfglet.2021.08.001

    Article  Google Scholar 

  16. Cheng X, Datta A, Choi H et al (2006) Study on embedding and integration of microsensors into metal structures for manufacturing applications. J Manuf Sci Eng 129:416–424. https://doi.org/10.1115/1.2515456

    Article  Google Scholar 

Download references

Acknowledgements

Work was supported through the Technology Commercialization Fund at INL. Government retains and the publisher, by accepting the article for publication, acknowledge that the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US Government purposes. We also acknowledge Asa Monson for his support during the execution of the experiment.

Funding

Work was supported through the through the Technology Commercialization Fund at INL.

Author information

Authors and Affiliations

  1. Digital Reactor Technology and Development, Idaho National Laboratory, Idaho Falls, ID, 83415, USA

    Luis Nuñez III

  2. Irradiation Experiment Thermal Hydraulics Analysis, Idaho National Laboratory, Idaho Falls, ID, 83415, USA

    Piyush Sabharwall

  3. Nuclear Sciences Division, Pacific Northwest National Laboratory, Richland, WA, 99352, USA

    Isabella J. van Rooyen

Authors
  1. Luis Nuñez III
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Piyush Sabharwall
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Isabella J. van Rooyen
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All the authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Luis Nuñez. The first draft of the manuscript was written by Luis Nuñez, and all the authors commented on previous versions of the manuscript. Piyush Sabharwall is responsible for funding acquisition. All the authors read and approved the final manuscript.

Corresponding author

Correspondence to Luis Nuñez III.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nuñez, L., Sabharwall, P. & van Rooyen, I.J. In situ embedment of type K sheathed thermocouples with directed energy deposition. Int J Adv Manuf Technol 127, 3611–3623 (2023). https://doi.org/10.1007/s00170-023-11624-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11624-6

Keywords

Search

Navigation