Integrating fiber optic sensors into metallic components for sensing in harsh environments

[Display omitted] •Sapphire fiber optic sensors were successfully integrated in spark plasma sintered stainless steel components for sensing in harsh environments.•Optical attenuation caused by the embedding process was limited (0.3 to 1.86 dB) and the level of attenuation was linked to embedding parameters.•Scanning electron microscopy revealed a good bond between the embedded fiber optic sensor and stainless steel matrix with interdiffusion across the interface.•Mechanical testing evidenced superior tensile properties and hardness of the fabricated stainless steel and sensor/matrix integrated materials. The integration of fiber optic sensors into high-temperature materials is critical for real-time monitoring and autonomous operation of engineering systems. This study demonstrated a spark plasma sintering (SPS)-assisted embedding process for integrating sapphire fiber optic sensors into stainless steel components during part fabrication. Optical fibers were encapsulated in stainless steel 316L powders which were sintered at different fabrication conditions using SPS to investigate the effects of sintering parameters on the embedment. Measurements of optical transmittance, combined with microstructural analysis (X-ray computed tomography and scanning electron microscopy) and mechanical testing (tensile and microhardness), were conducted to examine the fiber functionality, fiber–matrix bonding quality, and properties of the sintered materials. The results show that under suitable fabrication conditions, intact optical fibers can be encapsulated in highly-densified (>98 % relative density) stainless steel components. These conditions also led to a good bond at the fiber–matrix interface with micron-sized material interdiffusion across the interface. The sintering parameters were observed to affect fiber optical attenuation, where high temperature, pressure, and hold time during SPS enhanced fiber–matrix bonding and adversely affected optical transmission. Tensile testing confirmed the superior tensile strength and ductility of the matrix fabricated by SPS. Furthermore, the materials exhibited limited strength reduction (∼70 MPa) upon the integration of fibers. This study demonstrates the effectiveness of SPS for fiber-material integration for high-temperature applications.