Embedded metallized optical fibers for high temperature applications

Embedding fiber optics in metal components could enable new capabilities such as active monitoring of spatially distributed strain. Ultrasonic additive manufacturing is a suitable technique for embedding fiber optics because it allows fibers to be embedded in metals without melting and without the use of epoxy. However, for harsh environments that could have high temperatures or high radiation doses, traditional polymer-coated fibers cannot survive for extended periods of time. This work demonstrates successful embedding of commercially available copper-, nickel-, and aluminum-coated fibers into aluminum without any observable damage to the fiber. Copper-coated fibers embedded in copper show adequate light transmission, although residual strain could not be resolved. With further processing improvements, fibers embedded in copper or other high-temperature materials could enable even higher temperature operation. Optical transmission and spatially distributed strain were measured in the fibers embedded in aluminum. Measurements were taken after embedding and during heating to temperatures greater than 500 °C. Within the embedded region, both the copper- and aluminum-coated fibers showed strain that matched the expected strain in the surrounding aluminum matrix during heating. This suggests a strong interfacial bond strength that exceeds the maximum estimated fiber strain of 1.2% (871 MPa tensile stress). This demonstration of embedded fibers that can survive high temperatures and remain bonded to the metal matrix is the first step toward embedded fiber optic sensors for harsh environment applications.