One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This paper reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the Laser Engineered Net Shaping (LENS) process. Using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this paper demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

Brillouin optical time domain analysis is the sensing of temperature and strain changes along an optical fiber by measuring the frequency shift changes of Brillouin backscattering. Because frequency shift changes are a linear combination of temperature and strain changes, their discrimination is a challenge. Here, a multicore optical fiber that has two cores is fabricated. The differences between the cores’ temperature and strain coefficients are such that temperature (strain) changes can be discriminated with error amplification factors of 4.57 °C/MHz (69.11 $\mathsf{\mu }\mathsf{ϵ}$ /MHz), which is 2.63 (3.67) times lower than previously demonstrated. As proof of principle, using the multicore optical fiber and a commercial Brillouin optical time domain analyzer, the temperature (strain) changes of a thermally expanding metal cylinder are discriminated with an error of 0.24% (3.7%).