Surface-bonded and embedded optical fibers as ultrasonic sensors

The effectiveness of surface-bonded and embedded optical fibers for the detection of ultrasonic Lamb waves in 2-3-mm-thick steel, carbon-fiber-reinforced plastic (CFRP) and glass-reinforced plastic (GRP) plates are compared. A novel integrating ultrasonic sensor was achieved using the signal arm of an actively stabilized 633-nm homodyne Mach-Zehnder fiber interferometer which was either bonded directly to the plate surface or spliced to single-mode fibers embedded within a composite plate during manufacture. An embedded fiber is shown to be about 20 times more sensitive to Lamb wave motions than a surface-bonded fiber. However, the latter may be more practical.     

Computational Analysis and Optimization for Smart Patching Repairs

A classical cracked metallic structure, repaired with a smart bonded composite patch with embedded optical fibers (to detect the strain field variations of the loaded structure), has been studied here-in. Finite element analysis was used, where-in the composite patch was modeled as a layered structure with three-dimensional elements constituting six different laminae. Each lamina is assumed to have different mechanical properties, according to the studied case, in order to simulate different stacking sequence. A resin rich eye pocket has also been modeled in order to simulate the exact form of resin area produced during the manufacturing process. The patch is bonded over a cracked aluminum sheet through a small adhesive layer placed in between. External loads were applied only on the metal structure, as in a real repair case. The primary loading axis of the metal was assumed to be parallel to the direction of the optical fibers. Due to the different nature of the materials that form the composite patch, complex mechanical interactions between the fibers and the surrounding material occur, resulting in a complicated strain field along the optical fiber sensor. This affects the structural integrity of both the patch and the repair. Different optical fiber layer positions were considered, to study their effect on the resulting strain field and the structural integrity of the patch. Analysis concluded that the best available embedding position of an optical fiber in a laminated patch coincides to the one predicted as neutral surface, according to Rose's analytical equations.     

Strain measurement in a concrete beam by use of the Brillouin-scattering-based distributed fiber sensor with single-mode fibers embedded in glass fiber reinforced polymer rods and bonded to steel reinforcing bars

The strain measurement of a 1.65-m reinforced concrete beam by use of a distributed fiber strain sensor with a 50-cm spatial resolution and 5-cm readout resolution is reported. The strain-measurement accuracy is +/-15 microepsilon (microm/m) according to the system calibration in the laboratory environment with non-uniform-distributed strain and +/-5 microepsilon with uniform strain distribution. The strain distribution has been measured for one-point and two-point loading patterns for optical fibers embedded in pultruded glass fiber reinforced polymer (GFRP) rods and those bonded to steel reinforcing bars. In the one-point loading case, the strain deviations are +/-7 and +/-15 microepsilon for fibers embedded in the GFRP rods and fibers bonded to steel reinforcing bars, respectively, whereas the strain deviation is +/-20 microepsilon for the two-point loading case.     

Selection of Optical Fibers Paths and Sensor Locations for Monitoring the Integrity of Composite Patching

In order to select appropriate optical fiber paths and locations for Bragg Grating sensors, the research group has studied a classically cracked metallic structure repaired with a smart bonded composite patch using finite element analysis. The patch was bonded over a cracked aluminum plate by means of a thin adhesive layer. The primary loading axis of the metal was assumed parallel to the direction of the optical fibers used. A variety of optical fiber paths and sensor positions was considered, along with their ability to measure the developed strain field and to trace the position of the crack tip. It was concluded that a fiber optics network is indeed capable of tracing effectively the critical parameters required for the monitoring of structural integrity of the composite patch-reinforced structures (i.e. strains developed at the patch and at the tip of the crack). It was found that at least two Bragg Grating sensors should be used at each side of the crack per optical fiber, in order to enable adequate monitoring of the strain field and the position of the crack tip. Different locations should be chosen according to the configuration of the patch (one or two-sided).     

Damage detection of glass fiber reinforced composites using embedded PVA–carbon nanotube (CNT) fibers

Polyvinyl alcohol–carbon nanotube (PVA–CNT) fibers were embedded in glass fiber reinforced plastic composites and used as strain sensors for damage monitoring of the composite. Sensing of the structural integrity of the composite was made by the in situ measurement of the electrical resistance of the embedded PVA–CNT fiber during the mechanical tests. The multi-functional materials were tested in tensile progressive damage accumulation (PDA) tests. These tests aimed to seek the electrical response of untreated and pre-stretched PVA–CNT fibers with known level of progressively induced damage to the composite. The advantages and disadvantages of each PVA–CNT fiber used as a sensor are analyzed; the electrical resistance readings of the PVA–CNT fibers were correlated with known parameters that express the induced damage of the composite.     

Damage monitoring and analysis of composite laminates with an open hole and adhesively bonded repairs using digital image correlation

High performance composite materials, such as Carbon–Fibre Reinforced Plastic (CFRP) composites, are being increasingly used in aerospace industry, such as fuselage primary structures in Boeing 787 or Airbus 350, where high strength and stiffness are required at minimum weight [1]. The design of composite structures frequently includes discontinuities such as cut-outs for access and fastener holes for joining and they become critical regions under thermo-mechanical loading. Understanding of notched specimen behaviour is necessary for the design of complex structures where parts are mostly connected with bolts and rivets [2]. The effect of these discontinuities on the behaviour of composite materials is an important topic because it causes a relatively large reduction in strength compared to the unnotched laminate [3]. In the first part of the current work, the assessment of the damage process taking place in notched (open-hole) specimens under uniaxial tensile loading was studied. Two-dimensional (2D) and three-dimensional (3D) Digital Image Correlation (DIC) techniques were employed to obtain full-field surface strain measurements in carbon–fibre/epoxy M21/T700 composite plates with different stacking sequences in the presence of an open circular hole. Penetrant enhanced X-ray radiographs were taken to identify damage location and extent after loading around the hole. DIC strain fields were compared to numerical predictions. In the second part of the study, DIC techniques were used to characterise damage and performance of adhesively bonded patch repairs in composite panels under tensile loading. This part of work relates to strength/stiffness restoration of damaged composite aircraft that becomes more important as composites are used more extensively in the construction of modern jet airliners. In the current work, external bonded patches have been studied. Adhesively bonded repairs are the most common type of repair carried out with composite materials [1], [4]. The behaviour of bonded patches under loading was monitored using DIC full-field strain measurements. Location and extent of damage identified by X-ray radiography correlates well with DIC strain results giving confidence to the technique for structural health monitoring of bonded patches.     

Damage evaluation and strain monitoring for composite cylinders using tin-coated FBG sensors under low-velocity impacts

Background/purposeThe impact-induced damage of composite structures induced by low-velocity impacts were evaluated to verify the damage evaluation concept using the “memory effects” of tin-coated FBG sensors.MethodsLow-velocity impact tests for the composite cylinder with tin-coated FBG sensors were performed at three impact energies. Hoop ring tests for the composite cylinder including impact-induced damage were additionally undertaken in order to measure the burst pressure and to study the parameter correlations. The test results were compared with the numerical results obtained by a finite element analysis (FEA) based on a continuum damage mechanics (CDM) considering damage model. The parameter correlations among the impact parameters and the residual strains induced by tin-coated FBG sensors were investigated based on the tests results.ResultsImpact behaviors obtained by the tests and the numerical simulation were agreed well. It was found that tin-coated FBG sensors can monitor the strain of the composite cylinder under low-velocity impacts and their strain monitoring capability is comparable to that of normally used FBG sensors. The residual strains of tin-coated FBG sensors were correlated with the impact parameters such as the impact energy, the sensing position of the sensors, and the burst pressure of the composite cylinder.ConclusionThe correlations among the residual strains and the parameters proved the damage evaluation concept for composite cylinders using the “memory effects” of tin-coated FBG sensors under low-velocity impact conditions; that is, the impact-induced damage, impact location, and burst pressure can be inversely evaluated by referring to the correlations.     

Evaluation of the integrity of 3D orthogonal woven composites with embedded polymer optical fibers

Due to their high flexibility, high tensile strain and high fracture toughness, polymer optical fibers (POF) are excellent candidates to be utilized as embedded sensors for structure health monitoring of fiber reinforced composites. In 3D orthogonal woven structures yarns are laid straight and polymer optical fiber can be easily inserted during preform formation either as a replacement of constituents or between them. The results of the previous paper indicated how an optic fiber sensor can be integrated into 3D orthogonal woven preforms with no signal loss. This paper addresses whether incorporating POF into 3D orthogonal woven composites affects their structure integrity and performance characteristics. Range of 3D orthogonal woven composites with different number of layers and different weft densities was fabricated. The samples were manufactured with and without POF to determine the effect of embedding POF on composite structure integrity. Bending, tensile strength tests, and cross section analysis were conducted on the composite samples. Results revealed that integrity of 3D orthogonal woven composite was not affected by the presence of POF. Due to its high strain, embedded POF was able to withstand the stresses without failure as a result of conducting destructive tests of the composite samples. Micrograph of cross-section of composite samples showed that minimum distortion of the yarn cross-section in vicinity of POF and no presence of air pocked around the embedded POF which indicates that 3D woven preform provided a good host for embedded POF.     

Measurement of strain distributions near the steel/epoxy interface by micro-Raman spectroscopy under tensile load condition

Micro-Raman spectroscopy was applied for evaluating the stress distributions in the vicinity of the interface of the steel/epoxy bonded joint under tensile loading condition. Herein, single-walled carbon nanotubes (SWNTs) embedded in a polymer can be used as a mechanical sensor, in which the position of the D* Raman band varies with the strain or stress transferred to SWNTs from the surrounding matrix. In order to evaluate the strain distributions, however, it is required to elucidate the effect of the multiaxial stress on the D* band shift, because a multiaxial stress field appears in the vicinity of the interface and, the validity of this method has been confirmed only under uniaxial loading condition. Hence, at first, the D* band shift of a bulk epoxy/SWNT composite was measured under biaxial loading condition using a cruciform-type specimen. It was found that the D* band shift could be standardized in terms of the strain in the polarized direction even though under the biaxial condition. Then, on the basis of the result, this method was applied for evaluating the strain distributions of the steel/SWNT composite bonded joints under uniaxial tensile loading condition. The observation indicated that the strain singularity appeared in the vicinity of the interface, similar to the results of the finite-element analysis, and the observed strain almost agreed with calculated one in the range of 0.03–10 mm distance from the interface.     

Optimization of Embedded Optical Sensor Location in Composite Repairs

Optical fibers were embedded in a bonded composite patch in order to detect the strain field variations of a load bearing structure. The study concentrated on a classical cracked metallic structure repaired with this smart patch and using finite element analysis. Six different laminates constituted the model of the composite patch, a layered structure with three-dimensional elements. Each laminate is assumed to have different mechanical properties, according to the case under any specific study, in order to simulate different stacking sequence or material used. A resin rich eye pocket has also been modeled in order to simulate the exact form of the resin area produced during the manufacturing process. The patch is bonded over a cracked aluminum sheet through a small adhesive layer placed in between. External loads were applied only on the metal structure, as in a real repair case. The primary loading axis of the metal was assumed to be parallel to the direction of the optical fibers. The different nature of the materials that form the composite patch generated complex mechanical interactions between the fibers and the surrounding material, resulting in a complicated stress field along the optical fiber sensor, which affects the structural integrity of both the patch and the repair. Different optical fiber positions were considered, moving towards the horizontal and vertical dimensions of the patch, as well as different patch architectures (single and double patch configurations), with the hope of studying their effect on the structural integrity of the patch.     

Damage detection in holed composite laminates using an embedded FBG sensor

This paper discusses damage detection in a holed CFRP laminate under static and cyclic loading using an embedded fiber Bragg grating (FBG) sensor. In order to detect the damage extension in the laminate, the change in the spectrum shape was measured using an embedded FBG sensor and was compared with that obtained by numerical simulation. The shape of the reflection spectrum did not change during the cyclic load test; however, it did change with increased strain in the static load test, due to damage around the hole. To clarify this difference, the polished surface of the cross section of the specimen was analyzed. Debonding was observed between the optical fiber and matrix during the cyclic load test. These results lead us to conclude that fatigue damage around a hole in a composite laminate may not be detected with an FBG sensor due to the debondings.     

The mechanical behavior of optical fiber sensor embedded within the composite laminate

Mechanical behavior, such as tensile and fatigue strength, of the optical fiber sensor embedded within the composite laminate was investigated. Tensile and fatigue tests were performed to evaluate the static and fatigue characteristics of optical fibers embedded within three types of laminated composite specimens, [0₆/OF/0₆]_T, [0₂/90₄/OF/90₄/0₂]_T and [0₃/90₃/OF/90₃/0₃]_T. The initiation of damage and fracture of the optical fiber were detected by observation of the intensity drop-off of laser signal transmitted through the optical fiber during test. Experimental results showed that the fatigue strength of optical fiber embedded within the cross-ply laminate is much lower than the fatigue strength of optical fiber within the unidirectional ply laminate. It was also found that the optical fiber embedded within unidirectional ply laminate fractured due to the fatigue damage accumulation of internal defects of optical fiber itself. However the optical fiber embedded within the cross-ply laminate fractured due to the growth of transverse matrix crack of host composite laminate.     

Characterization of microscopic damage in composite laminates and real-time monitoring by embedded optical fiber sensors

First, a methodology for observation and modeling of microscopic damage evolution in quasi-isotropic composite laminates is presented. Based on the damage observation using both an optical microscope and a soft X-ray radiography, a damage mechanics analysis is conducted to formulate the stiffness change due to transverse cracking. Then, both energy and stress criteria are combined to provide a valid procedure to predict the transverse crack evolution. The theoretical prediction is found to agree well with the experimental results for the transverse crack density as a function of strain as well as stress–strain curves. Then, another methodology is introduced using two kinds of embedded optical fiber sensors to detect and monitor the transverse crack evolution in composite laminates. One is plastic optical fibers (POF), where the loss in optical power is generated by local deformation of POF due to transverse cracking. The other is fiber Bragg grating (FBG) sensors, where the local strain distribution within the FBG gage length due to transverse cracking alters the power spectrum of the light reflected from the FBG sensors. Embedded optical fiber sensors are found to be a powerful method to detect and monitor the transverse crack evolution in composite laminates.     

Structural health monitoring of glass fiber reinforced composites using embedded carbon nanotube (CNT) fibers

In the present work, carbon nanotube (CNT) fibers had been embedded to glass fiber reinforced polymers (GFRP) for the structural health monitoring of the composite material. The addition of the conductive CNT fiber to the non-conductive GFRP material aims to enhance its multi-function ability; the test specimen’s response to mechanical load and the insitu CNT fiber’s electrical resistance measurements were correlated for sensing and damage monitoring purposes. It is the first time this fiber is used in composite materials for sensing purposes; CNT fiber is easy to be embedded and does not downgrade the material’s mechanical properties. Various incremental loading–unloading steps had been applied to the manufactured specimens in tension as well as in three-point bending tests. The CNT fiber worked as a sensor in both, tensile and compression loadings. A direct correlation between the mechanical loading and the electrical resistance change had been established for the investigated specimens. For high stress (or strain) level loadings, residual resistance measurements of the CNT fiber were observed after unloading. Accumulating damage to the composite material had been calculated and was correlated to the electrical resistance readings. The established correlation between these parameters changed according to the material’s loading history.     

Strain monitoring in composite-strengthened concrete structures using optical fibre sensors

In this paper, the mechanical behaviour of the composite-strengthened concrete structures is addressed. Optical fibre sensor presents a great deal of potential in monitoring the structural health condition of civil infrastructure elements after strengthening by externally bonded composite materials. The use of embedded optical fibre sensor for strain and temperature monitoring enables to reveal the status of the composite-strengthened structure in real-time remotely. In this paper, an experimental investigation on the composite-strengthened concrete structures with the embedment of fibre-optic Bragg grating (FBG) sensors is presented. Single- and multiplexed-point strain measuring techniques were used to measure strains of the structures. Frequency modulated continuous wave (FMCW) method was used to measure strains in different points of the structure with using only one single optical fibre. All strains measured from the sensors were compared to conventional surface mounted strain gauges. Experimental results show that the use of the embedded FBG sensor can measure strain accurately and provide information to the operator that the structure is subjected to debond or micro-crack failure. Multiplexed FBG strain sensors enable to measure strain in different locations by occupying only one tiny optical fibre. Reduction of strength in composite laminate is resulted if the embedded optical fibre is aligned perpendicular to the load-bearing direction of the structure.     

The mechanical characteristics of smart composite structures with embedded optical fiber sensors

In this study, the mechanical characteristics of composite laminates with embedded optical fiber sensors were evaluated to investigate the effect of embedded optical fiber on the mechanical properties of composite laminates under the static tensile and the low cycle fatigue load. Testing specimens were fabricated with glass fiber/epoxy composites with embedded optical fiber sensors to observe initiation and growth of damage in the specimens and laser signal behavior transmitted through the optical fiber visually and directly. By using this transparency of glass fiber/epoxy composites, the damage of sensors and associated laser signal behavior was observed. Under the static load, the embedded optical fibers do not have significant effect on the stiffness and the strength, while the embedded optical fibers show significant effect on the fatigue life of composite specimens. Especially, the embedded optical fiber sensors show the very low resistance to the fatigue load.     

Damage to flax fibre slivers under monotonic uniaxial tensile loading

Usual testing methods developed for synthetic fibre bundles or slivers do not suit for plant fibres which exhibit specific characteristics. This paper reports damage investigation in flax fibre slivers (collection of disentangled and aligned fibre bundles more or less bonded by bark residues or other tissues) especially prepared for uniaxial tension testing using a new methodology and a dedicated device.The analysis of the acoustic emission data by using clustering methodology allowed categorizing three populations of damage mechanisms. Identification of the damage mechanisms was made by correlation of the tensile loading curves with acoustic emission data and by optical observations. Different damage parameters defined from the mechanical data (released elastic energy) were compared with those from acoustic data (energy of the hits). The results showed that the extension of damage vs. deformation can be expressed by using either of these two data sets.     

Effect of oxygen plasma treatment of PPTA and PBO fibers on the interfacial properties of single fiber/epoxy composites studied by Raman spectroscopy

The interfacial micromechanics of single poly(p-phenylene terephthalamide (PPTA) and poly(p-phenylene benzobisoxazole (PBO) fibers embedded in an epoxy resin has been investigated by determining the interfacial shear stress distributions along the fiber length. The effects of an oxygen plasma treatment on the interfacial shear stress of the fiber-epoxy systems are analyzed. Raman spectroscopy was used to map the stress distributions along the fiber when the composite is subjected to a small axial tensile strain (3.5% for PPTA and 2.5% for PBO). The quality of the interface or adhesion was improved after the surface treatment, supporting the ability of plasma oxidation to enhance the adhesion of high-performance fibers to epoxy resins. The tensile behavior of fiber-reinforced systems was different in each case. PPTA reinforcements underwent fragmentation, likely by fiber microfailure, whereas debonding or bridging is the most probable fragmentation mechanism in the case of PBO.     

Numerical optimization of strengthening disturbed regions of dapped-end beams using NSM and EBR CFRP

This paper presents a parametric investigation, based on non-linear finite element modeling, to identify the most effective configuration of carbon fiber-reinforced polymers (CFRP) for strengthening reinforced concrete (RC) dapped-end beams. Following a field application and laboratory tests, it focuses on effects of 24 externally bonded (EBR) and near surface mounted reinforcement (NSMR) configurations on yield strain in steel and the capacity and failure mode of dapped-end beams. The investigated parameters were the mechanical properties of the CFRP, the strengthening procedure and the inclination of the fibers with respect to the longitudinal axis. Two failure scenarios were considered: rupture and debonding of the FRP. The results indicate that high-strength NSM FRPs can considerably increase the capacity of dapped-end beams and the yielding strains in reinforcement can be substantially reduced by using high modulus fibers.     

Method for embedding optical fibers in an aluminum matrix by ultrasonic consolidation

The overall aim of the research, part of which is outlined in this paper, was to utilize the ultrasonic consolidation (UC) process for the fabrication of smart metal structures, capable of measuring an external stimulus and responding to this stimulus by adapting its structure accordingly through embedding both active and passive functional elements. This paper presents a fundamental study of embedding methods for the fabrication of optical fibers embedded within aluminum structures. The methods considered in this paper produced embedded optical fiber specimens in which large amounts of plastic flow were observed within the matrix. The matrix material deformed around the fibers, resulting in fully embedded optical fibers capable of transmitting a bright light source and without damaging the fibers. Based on light responses, a general process window was drawn to show the range at which optical fibers can be embedded within aluminum structures using the UC process. The outcomes lay down initial investigative principles for the further development of the technology for embedding or cladding of optical fiber sensors, such as fiber Bragg grating devices, within or on metal structures: for example, the cladding of large free-form metal structures or smart "skinned" metal foam or metal honeycomb structures.