A Multifunctional Smart Metal Beam with Sub-Surface Embedded Sensors for Real-Time Structural Health Monitoring

Abstract

Smart Metallic Structures (SMS) with embedded sensors have gained significant at- tention for Structural Health Monitoring (SHM) applications. This study develops a “Smart Beam” with sub-surface embedded sensors, fabricated through a hybrid manu- facturing approach that integrates additive and subtractive techniques. The sensor net- work comprises commercial off-the-shelf (COTS) sensors, including strain gauges and resistance temperature detectors (RTDs), embedded into an additively manufactured aluminum beam (Al 5356) for real-time structural health and environmental monitoring. To evaluate its performance and reliability, the fabricated beam is subjected to a series of SHM assessments, including steady-state heating, transient heating, and three-point bending experiments. The results from these tests confirm the Smart Beam’s structural integrity and sensor functionality, with quantitative assessments indicating high-fidelity temperature measurements (≤ 0.5% error) and consistent strain response under both the linear and failure regions. Despite a moderate mechanical debit—20.6% reduction in flexural modulus and 18.9% in yield strength—the Smart Beam effectively captured both mechanical and thermal responses throughout testing, confirming its functional integrity and sensing reliability. The developed Smart Beam, along with its hybrid manufacturing approach, holds significant potential for advanced SHM applications.