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This paper proposes a novel method to impart intelligence to metal parts using additive manufacturing. A sensor-embedded metal bracket is prototyped via a metal powder bed fusion process to recognise partial screw loosening or total screw missing or identify the source of vibration with the assistance of artificial intelligence (AI). The digital metal bracket can recognise subtle changes in the screw fixation state with 90% accuracy and identify unknown sources of vibration with 84% accuracy. The von Mises stress distribution in the prototyped metal bracket is evaluated using a finite element analysis, which is learned by AI to match the real-time deformation analysis of the metal bracket in augmented reality. The proposed prototype can contribute to hyper-connectivity for developing next-generation metal-based mechanical components. [ABSTRACT FROM AUTHOR]

Artificial intelligence and Internet of Things (IoT) technology, which are the core of the 4th industrial revolution, can resolve many problems that optimization of production times in the manufacturing process and reduction of materials required etc. In order to utilize the 4th industrial revolution technology, real-time monitoring technology of metal parts is essential, so technology for embedding sensors and IC chips into parts is essential. Using metal 3d printing technology, it is possible to embed IC chips into metal parts, which was impossible because of the existing high-temperature metal manufacturing process of casting or forging. Here we introduce a novel new method for sensor embedding into SUS316L by hemisphere design to avoid direct laser exposure onto sensors during selective laser melting process. Thermal and microstructural analysis was carried out to characterize the property of inner hemisphere for safe thermal couple embedding into SUS316L. [ABSTRACT FROM AUTHOR]

Fiber reinforced composites combine low density with high specific mechanical properties and thus became indispensable for today's lightweight applications. In particular, carbon fibre reinforced plastic (CFRP) is broadly used for aerospace components. However, damage and failure behaviour, especially for complex fibre reinforcement set-ups and under impact loading conditions, are still not fully understood yet. Therefore, relatively large margins of safety are currently used for designing high-performance materials and structures. Technologies to functionalise the materials enabling the monitoring of the structures and thus avoiding critical conditions are considered to be key to overcoming these drawbacks. For this, sensors and actuators are bonded to the surface of the composite structures or are integrated into the composite lay-up. In case of integration, the impact on the mechanical properties of the composite materials needs to be understood in detail. Additional elements may disturb the composite structure, impeding the direct connection of the composite layers and implying the risk of reducing the interlaminar integrity by means of a lower delamination resistance. In the presented study, the possibility of adjusting the interface between the integrated actuator and sensor layers to the composite layers is investigated. Different polymer layer combinations integrated into carbon fibre reinforced composite layups are compared with respect to their interlaminar critical energy release rates G I c and G I I c . A standard aerospace unidirectionally reinforced (UD) CFRP prepreg material was used as reference material configuration. The investigations show that it is possible to enhance the mechanical properties, especially the interlaminar energy release rate by using multilayered sensor–actuator layers with Polyimide (PI) outer layers and layers with low shear stiffness in between. [ABSTRACT FROM AUTHOR]