Towards smart bits: monitoring temperature and load by embedding sensors within rotary blast drill bits

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This project aims at developing a technology for embedding fiber Bragg grating (FBG) sensors within metallic structures. The candidate structure is a rotary blast drilling bit, for which a simultaneous measurement of load and temperature in critical locations is required for the assessment of its performance in-service. The technology developed in this research program will facilitate the long-term objective of the research group, which is an introduction of a reliable technique for embedding sensors within metallic structures. The requirements to obtain information on the performance and lifetime of metallic tools in-service can be addressed by the use of embedded sensors which enable the monitoring of physical parameters at locations not accessible by ordinary sensors.        To arrive at the proposed objective, laser-assisted maskless microdeposition (LAMM) will be characterized to successfully coat the FBG sensors with nano-particles of metallic elements (e.g., silver, copper). Depositing a thin layer of conductive element will allow the use of the electroplating technique for further depositing engineered materials to create a protective layer on the FBG sensors.  The laser solid freeform fabrication (LSFF) technique will then be utilized to perform final deposition of Stellite 6 on the sensor which is placed within the drill bits. In the proposed research program, the interactions between various systems and materials involved in both LAMM and LSFF technologies will be studied theoretically and experimentally to develop a new paradigm for the successful application of the technology in the fabrication of metallic structures with embedded fiber optic sensors. Assessment of the fabricated metallic structures in-service will be conducted to measure the sensitivity of the embedded sensors.        The proposed research is the first-of-kind in Canada and will result in an advanced technology for the fabrication of metallic structures with embedded sensors. The benefits of this project are pervasive and can be used in many industries including die manufacturing, automotive, aerospace, and others.