Advanced ceramic components with embedded sapphire optical fiber sensors for high temperature applications

This paper describes an extrusion-based additive manufacturing process that has been developed to enable embedment of sapphire optical fiber sensors in ceramic components during the part fabrication. In this process, an aqueous paste of ceramic particles is extruded through a moving nozzle to build the part layer-by-layer. In the case of sensor embedment, the fabrication process is halted after a certain number of layers have been deposited; the sensors are placed in their predetermined locations, and the remaining layers are deposited until the part fabrication is completed. Because the sensors are embedded during the fabrication process, they are fully integrated with the part and the problems of traditional sensor embedment can be eliminated. Scanning electronmicroscopy was used to observe the embedded sensors and to detect any possible flaws in the part or embedded sensor. Attenuation of the sensors was measured in near-infrared region (1500-1600 nm wavelength). Standard test methods were employed to examine the effect of embedded fibers on the strength and hardness of the parts. The results indicated that the sapphire fiber sensors with diameters smaller than 250 micrometers were able to endure the freeform extrusion fabrication process and the post-processing without compromising the part properties. Published by Elsevier Ltd.