During the last decades, structural health monitoring (SHM) systems are used in order to detect damage in structures. We have developed a novel structural health monitoring approach, the so-called “effective structural health monitoring” (eSHM) system. The current SHM system is incorporated into a metallic structure by means of additive manufacturing (AM) and has the possibility to advance life safety and reduce direct operative costs. It operates based on a network of capillaries that are integrated into an AM structure. The internal pressure of the capillaries is continuously monitored by a pressure sensor. When a crack nucleates and reaches the capillary, the internal pressure changes signifying the existence of the flaw. The main objective of this paper is to evaluate the crack detection capacity of the eSHM system and crack location accuracy by means of various non-destructive testing (NDT) techniques. During this study, detailed acoustic emission (AE) analysis was applied in AM materials for the first time in order to investigate if phenomena like the Kaiser effect and waveform parameters used in conventional metals can offer valuable insight into the damage accumulation of the AM structure as well. Liquid penetrant inspection, eddy current and radiography were also used in order to confirm the fatigue damage and indicate the damage location on un-notched four-point bending AM metallic specimens with an integrated eSHM system. It is shown that the eSHM system in combination with NDT can provide correct information on the damage condition of additive manufactured metals.

Selective laser melting (SLM) is an additive manufacturing (AM) process which is used for producing metallic components. Currently, the integrity of components produced by SLM is in need of improvement due to residual stresses and unknown fracture behavior. Titanium alloys produced by AM are capable candidates for applications in aerospace and industrial fields due to their fracture resistance, fatigue behavior and corrosion resistance. On the other hand, structural health monitoring (SHM) system technologies are promising and requested from the industry. SHM systems can monitor the integrity of a structure and during the last decades the research has primarily been influenced by bionic engineering. In that aspect a new philosophy for SHM has been developed: the so-called effective structural health monitoring (eSHM) system. The current system uses the design freedom provided by AM. The working principle of the system is based on crack detection by means of a network of capillaries that are integrated in a structure. The main objective of this research is to evaluate the functionality of Ti6Al4V produced by the SLM process in the novel SHM system and to confirm that the eSHM system can successfully detect cracks in SLM components. In this study four-point bending fatigue tests on Ti6Al4V SLM specimens with an integrated SHM system were conducted. Fractographic analysis was performed after the final failure, while finite element simulations were used in order to determine the stress distribution in the capillary region and on the component. It was proven that the SHM system does not influence the crack initiation behavior during fatigue. The results highlight the effectiveness of the eSHM on SLM components, which can potentially be used by industrial and aerospace applications.

The study describes the acoustic emission (AE) activity during human femur tissue fracture. The specimens were fractured in a bending-torsion loading pattern with concurrent monitoring by two AE sensors. The number of recorded signals correlates well with the applied load providing the onset of micro-fracture at approximately one sixth of the maximum load. Furthermore, waveform frequency content and rise time are related to the different modes of fracture (bending of femur neck or torsion of diaphysis). The importance of the study lies mainly in two disciplines. One is that, although femurs are typically subjects of surgical repair in humans, detailed monitoring of the fracture with AE will enrich the understanding of the process in ways that cannot be achieved using only the mechanical data. Additionally, from the point of view of monitoring techniques, applying sensors used for engineering materials and interpreting the obtained data pose additional difficulties due to the uniqueness of the bone structure.

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.

Numerous structural health monitoring systems have been investigated extensively in order to enhance safety level and reduce direct operational costs. This work demonstrates the feasibility study of a new concept, the effective structural health monitoring system. The effective structural health monitoring system detects cracks using a system of capillaries incorporated into a structure. The structure with the integrated capillaries is produced by additive manufacturing, a process of adding material layer by layer. The first objective of this study is to prove that the developed system has reached technological readiness level 3. In order to prove that, four-point bending specimens with the integrated effective structural health monitoring system were tested after being produced by additive manufacturing, more specifically by laser metal deposition. The second objective of the study is to indicate that during four-point bending fatigue tests, the integrated structural health monitoring system has no influence on the crack initiation behavior. To do so, the specimens were subjected to the so-called step method. We demonstrate that the effective structural health monitoring has reached technological readiness level 3 and that the presence of effective structural health monitoring did not negatively influence the fatigue initiation process. As higher technology readiness levels are required, further investigations are still in progress.