Smart BuildPlate for Metal Additive Manufacturing Processes This paper discusses the development, processing steps, and evaluation of a smart buildplate or baseplate tool for metal additive manufacturing technologies. This tool uses an embedded highdefinition fiber optic sensing fiber to measure strain states from temperature and residual stress within the buildplate for monitoring purposes. Monitoring entails quality tracking for consistency along with identifying defect formation and growth, i.e., delamination or crack events near the buildplate surface. An aluminum alloy 6061 buildplate was manufactured using ultrasonic additive manufacturing due to the processxe2x80x99 low formation temperature and capability of embedding fiber optic sensing fiber without damage. Laserpowder bed fusion (LPBF) was then used to print problematic geometries onto the buildplate using AlSi10Mg for evaluation purposes. The tool identified heat generation, delamination onset, and delamination growth of the printed LPBF parts.

Smart Adhesive Joint with HighDefinition FiberOptic Sensing for Automotive Applications Structural health monitoring of fiberreinforced compositebased joints for automotive applications during their manufacturing and ondemand assessment for its durability in working environments is critically needed. Highdefinition fiberoptic sensing is an effective method to measure internal strainstress development using minimally invasive continuous sensors. The sensing fiber diameters are in the same order of magnitude when compared to reinforcement (glass, basalt, or carbon fibers) used in polymer composites. They also offer a unique ability to monitor the evolution of residual stresses after repeated thermal exposure with varying temperatures for automotive componentsjoints during painting using an electrophoretic painting process. In this paper, a highdefinition fiberoptic sensor utilizing Rayleigh scattering is embedded within an adhesive joint between a carbon fiberreinforced thermoset composite panel and an aluminum panel to measure spatially resolved strain development, residual strain, and thermal expansion properties during the electrophoretic paint processsimulated conditions. The strain measured by the continuous fiberoptic sensor was compared with an alternate technique using thermal digital image correlation. The fiberoptic sensor was able to identify the spatial variation of residual strains for a discontinuous carbon fiberreinforced composite with varying local fiber orientations and resin content.