Experimental investigations in embedded sensing of composite components in aerospace vehicles

This paper summarizes the experimental investigations for smart embedded sensing in rotorcraft composite components. The overall objective of this effort was to develop smart embedded sensor technologies for condition based maintenance (CBM) for composite components in army rotorcraft. This paper presents the results of experimental investigations related to development and maturation of different types of embedded sensing solutions for structural health monitoring of composite components including Fiber Bragg Grating (FBG) sensors, phased and discrete piezoelectric sensor arrays. A discussion is provided relative to embedment of optical fibers into composites, and the results from embedded FBG sensors in a rotorcraft flexbeam subcomponent test specimen with seeded delamination subjected to dynamic loading. Likewise, results are analyzed of surface mounted phased array and embedded smart piezoelectric sensors in the flexbeam subcomponent test specimen with embedded delamination, subjected to fatigue cyclic loading. The paper also summarizes the lessons learned from efforts to nucleate and propagate delamination within composite components under dynamic cyclic loading.     

An overview of wireless structural health monitoring for civil structures

Wireless monitoring has emerged in recent years as a promising technology that could greatly impact the field of structural monitoring and infrastructure asset management. This paper is a summary of research efforts that have resulted in the design of numerous wireless sensing unit prototypes explicitly intended for implementation in civil structures. Wireless sensing units integrate wireless communications and mobile computing with sensors to deliver a relatively inexpensive sensor platform. A key design feature of wireless sensing units is the collocation of computational power and sensors; the tight integration of computing with a wireless sensing unit provides sensors with the opportunity to self-interrogate measurement data. In particular, there is strong interest in using wireless sensing units to build structural health monitoring systems that interrogate structural data for signs of damage. After the hardware and the software designs of wireless sensing units are completed, the Alamosa Canyon Bridge in New Mexico is utilized to validate their accuracy and reliability. To improve the ability of low-cost wireless sensing units to detect the onset of structural damage, the wireless sensing unit paradigm is extended to include the capability to command actuators and active sensors.     

Monitoring of Impacted Aramid-Reinforced Composites by Embedded PVDF Acoustic Emission Sensors

Abstract:  An embedded piezoelectric [poly(vinylidene fluoride) (PVDF)] thin film sensors system for acoustic emission (AE) was realized to investigate the possibility of monitoring, in real time, the post-impact damage in aramid woven fabric-reinforced epoxy. The same sensors have been used in a previous work on similar specimens tested in flexure but not previously impacted, with the aim of verifying the suitability of these sensors to be embedded and their ability to detect AE signals under loading. This work is a continuation of the previous one aiming at evaluating the ability of these embedded PVDF sensors to point out the presence of impact damage, issue widely studied in literature. Aramid fibre/epoxy composite specimens with embedded PVDFs, previously impacted at different energies, namely 5, 10 and 15 J, were tested using three-point bending tests. It appeared from mechanical tests that the flexural strength decreased passing from non-impacted specimens to those impacted with the highest energy and that the embedment of PVDFs in the laminates did not markedly affect the structural integrity of the impacted composites. The degree of impact damage, represented by the decrease in mechanical properties, has been correlated with the AE activity by means of a parametric analysis of the AE signals detected during post-impact mechanical tests.     

Strain and damage sensing properties on multifunctional cement composites with CNF admixture

Both strain and damage sensing properties on carbon nanofiber cement composites (CNFCCs) are reported in the present paper. Strain sensing tests were first made on the material’s elastic range. The applied loading levels have been previously calculated from mechanical strength tests. The effect of several variables on the strain-sensing function was studied, e.g. cement pastes curing age, current density, loading rate or maximum stress applied. All these parameters were discussed using the gage factor as reference. After this first set of elastic experiments, the same specimens were gradually loaded until material’s failure. At the same time both strain and resistivity were measured. The former was controlled using strain gages, and the latter using a multimeter on a four probe setup. The aim of these tests was to prove the sensitivity of these CNF composites to sense their own damage, i.e. check the possibility of fabricating structural damage sensors with CNFCC’s. All samples with different CNF dosages showed good strain-sensing capacities for curing periods of 28 days. Furthermore, a 2% CNF reinforced cement paste has been sensitive to its own structural damage.     

Polymer-Grafted,Gold Nanoparticle-Based Nano-Capsules as Reversible Colorimetric Tensile Strain Sensors

Colloidal colorimetric microsensors enable the in-situ detection of mechanical strains within materials. Enhancing the sensitivity of these sensors to small scale deformation while enabling reversibility of the sensing capability would expand their utility in applications including biosensing and chemical sensing. In this study, we introduce the synthesis of colloidal colorimetric nano-sensors using a simple and readily scalable fabrication method. Colloidal nano sensors are prepared by emulsion-templated assembly of polymer-grafted gold nanoparticles (AuNP). To direct the adsorption of AuNP to the oil-water interface of emulsion droplets, AuNP (≈11nm) are functionalized with thiol-terminated polystyrene (PS, M_n = 11k). These PS-grafted gold nanoparticles are suspended in toluene and subsequently emulsified to form droplets with a diameter of ≈30µm. By evaporating the solvent of the oil-inwater emulsion, we form nanocapsules (AuNC) (diameter < 1µm) decorated by PS-grafted AuNP. To test mechanical sensing, the AuNC are embedded in an elastomer matrix. The addition of a plasticizer reduces the glass transition temperature of the PS brushes, and in turn imparts reversible deformability to the AuNC. The plasmonic peak of the AuNC shifts towards lower wavelengths upon application of uniaxial tensile tension, indicating increased inter-nanoparticle distance, and reverts back as the tension is released.     

轿车发动机电控喷射系统用新型传感器的开发

天津大学在国家“８６３”新材料领域的资助下，研制开发新型氧敏薄膜材料，研制出近百个Ａ／Ｆ传感器样件。该样件材料新颖，结构简单，响应速度快，成本低，具有独立知识产权。装在夏利车上，与国外生产进行了排放控制试验比较。试验结果表明，控制能力达到国外生产件水平；响应速度比后者快。     

An experimental–numerical investigation of hydrothermal response in adhesively bonded composite structures

Water absorption and thermal response of adhesive composite joints were investigated by measurements and numerical simulations. Water diffusivity, saturation, swelling, and thermal expansion of the constituent materials and the joint were obtained from gravimetric experiments and strain measurements using embedded fiber Bragg grating (FBG) sensors. The mechanical response of these materials at different temperatures and water content was characterized by dynamic mechanical analysis. Thermal loading and water absorption in joint specimens were detected by monitoring the FBG wavelength shift caused by thermal expansion or water swelling. The measured parameters were used in finite element models to simulate the response of the embedded sensor. The good correlation of experimental data and simulations confirmed that the change in FBG wavelength could be accurately related to the thermal load or water absorption process. The suitability of the embedded FBG sensors for monitoring of water uptake in adhesive composite joints was demonstrated.     

Novel 3D‐Printed Hybrid Auxetic Mechanical Metamaterial with Chirality‐Induced Sequential Cell Opening Mechanisms

New hybrid auxetic chiral mechanical metamaterial are designed and fabricated via multi‐material 3D printing. Due to the chirality‐induced rotation, the material have unique sequential cell‐opening mechanisms. Mechanical experiments on the 3D printed prototypes and systematic FE simulations show that the effective stiffness, the Poisson's ratio and the cell‐opening mechanisms of the new design can be tuned in a very wide range by tailoring two non‐dimensional parameters: the cell size ratio and stiffness ratio of component materials. As example applications, sequential particle release mechanisms and color changing mechanisms of the new designs are also systematically explored. The present new design concepts can be used to develop new multi‐functional smart composites, sensors and/or actuators which are responsive to external load and/or environmental conditions for applications in drug delivery and color changing for camouflage.

     

Fibre Optic Protection System for Concrete Structures

The design concepts, modelling and implementation of various fibre optic sensor protection systems for development in concrete structures were investigated. Design concepts and on-site requirements for surface-mounted and embedded optical fibre sensor in concrete were addressed. Finite element （FE） modelling of selected sensor protection systems in strain-transfer efficiency from the structure to the sensing region was also studied. And experimental validation of specified sensor protection system was reported. Results obtained indicate that the protection system for the sensors performs adequately in concrete environment and there is very good correlation between results obtained by the protected fibre optic sensors and conventional electrical resistance strain gauges.     

Development of smart composite structures with small-diameter fiber Bragg grating sensors for damage detection: Quantitative evaluation of delamination length in CFRP laminates using Lamb wave sensing

The authors and Hitachi Cable, Ltd. have recently developed small-diameter optical fiber and its fiber Bragg grating (FBG) sensor for embedment inside a lamina of composite laminates without strength reduction. The outside diameters of the cladding and polyimide coating are 40 and 52 μm, respectively. First, a brief summary is presented for applications of small-diameter FBG sensors to damage monitoring in composite structures. Then, we propose a new damage detection system for quantitative evaluation of delamination length in CFRP laminates using Lamb wave sensing. In this system, a piezo-ceramic actuator generates Lamb waves in a CFRP laminate. After the waves propagate in the laminate, transmitted waves are received by an FBG sensor attached on or embedded in the laminate using a newly developed high-speed optical wavelength interrogation system. This system was applied to detect interlaminar delamination in CFRP cross-ply laminates. When the Lamb waves passed through the delamination, the amplitude decreased and a new wave mode appeared. These phenomena could be well simulated using a finite element analysis. From the changes in the amplitude ratio and the arrival time of the new mode depending on the delamination length, it was found that this system could evaluate the delamination length quantitatively. Furthermore, small-diameter FBG sensors were embedded in a double-lap type coupon specimen, and the debonding progress could be evaluated using the wavelet transform.     

Strain monitoring of carbon fiber composite via embedded nickel nano-particles

Piezoresistive embedded sensors in carbon fiber reinforced plastic (CFRP) composites have the potential of providing a further multi-functional property to an extremely adaptable material. In this paper a conductive patch of nickel nanostrands embedded in carbon fiber composites displays repeatable piezoresistivity, thus becoming a strain sensor capable of accurately measuring strain, real time and in situ. This patch has compatible mechanical properties to existing advanced composites and shows good resolution to small strain. This method of strain sensing in carbon fiber composites is more easily implemented and used than other strain measurement methods including fiber Bragg grating and acoustic emissions.     

Acoustic and Optical VOCs Sensors Incorporating Carbon Nanotubes

The authors investigate the sensing properties of single-walled carbon nanotubes (SWCNTs) films, which are used as nanostructured materials for chemical sensors onto three types of transducers using different principles of operation as surface acoustic waves (SAWs), quartz-crystal microbalance (QCM), and a standard silica optical fiber (SOF) for detection of volatile organic compounds at a room temperature. The sensing probes have been configured as 315- and 433-MHz SAW two-port resonator-based oscillator, 10-MHz QCM resonator, and SOF light-reflectometry-based system at a wavelength of 1310 nm. A nanocomposite film of SWCNTs embedded in a cadmium-arachidate matrix was deposited by Langmuir-Blodgett (LB) technique onto the SAW sensors. An LB multilayer of SWCNTs-onto-CdA buffer material was also deposited onto the QCM and SOF sensors. The experiments demonstrate that carbon-nanotubes acoustic and optical sensors are highly sensitive to a wide range of polar and nonpolar organic solvents up to a sub-ppm detection limit at a room temperature.     

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.     

Tailoring Thin‐Film Piezoelectrics for Crash Sensing

Crash sensing and its assessment play a pivotal role in autonomous vehicles for preventing fatal casualties. Existing crash sensors are severely bottlenecked by sluggish response time, rigid mechanical components, and space constraints. Miniaturized sensors embedded with custom‐tailored nanomaterials upholds potential to overcome these limitations. In this article, piezoelectric Zinc‐Oxide thin film as a crash sensing layer is integrated onto a flexible metal‐alloy cantilever. Material characterization studies are conducted to confirm piezoelectric property of sputtered ZnO film. The piezoelectric d ₃₁ coefficient value of ZnO film was 7.2 pm V^–1. The ZnO sensing element is firmly mounted on a scaled car model and used in a crash sensing experimental set‐up. A comprehensive theoretical analysis for two different real scenarios (nearly elastic and nearly inelastic collision) of crash events followed by experimental study is discussed. The crash sensor's output exhibits a linear relationship with magnitude of impact forces experienced at crash events. The response time of ZnO crash sensor is 18.2 ms, and it exhibits a sensitivity of 28.7 mV N^–1. The developed crash sensor has potential to replace bulk material sensors owing to its faster response time, high sensitivity, and compactness as the demand for crash sensors in next‐generation automobile industries is progressively growing.     

埋入CFRP的FBG光纤传感器界面传递特性实验研究

埋入碳纤维复合材料（CFRP）的光纤布拉格光栅（FBG）传感器应变测量值与基体实际应变存在误差,用光纤、保护层、粘贴层和基体材料的界面传递特性来表征应变测量值可提高精度．根据弹性力学和边界条件,得出FBG应变测量值与基体材料实际应变值的关系方程,通过裸光栅直埋基体材料界面传递的特征系数,可表征和计算FBG检测应变与测点实际应变的误差及修正系数．试验结果表明：对埋入裸光栅的碳纤维复合材料同时进行电阻应变与FBG—IS波长解调试验对比,试验测量FBG应变传感灵敏系数与理论值十分接近;对埋入CFRP的FBG裸光栅,由于不存在粘贴层界面传递的影响,其应变测量值可无需修正．     

A VHDL Model of a IEEE1451.2 Smart Sensor: Characterization and Applications

New sensors are required to be small, cheap, and smart. This paper deals with intelligent sensors embedded in a single chip: a VHDL model of an IEEE1451.2 Smart Sensor is proposed to obtain a portable STIM block suitable for customizable compact solutions and allowing low-cost, large-scale production. In order to evaluate performances of the proposed model, working prototypes have been built and some tests have been carried out in a real case (chemical detection sensors). The proposed VHDL model has been compared with traditional, software-based, microcontroller solutions showing that a timing performance improvement greater than 50% can be obtained. Finally, to exemplify effectiveness of a portable VHDL model, a single-chip sensor with USB interface and integrated IEEE1451 structures has been realized and experimentally characterized     

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.     

Embedded Sensors in Rubber and Other Polymer Components

Abstract: Many polymer components are susceptible to catastrophic failure or are critical to the performance of the products they comprise. Because of this, the capability to monitor structural failures or performance reduction in these components is beneficial. It is difficult to fabricate sensors for polymer components because they often have complex shapes or are assembled in isolated locations. To solve this problem, micro‐scale electronic sensors, embedded within polymer components, were developed at Purdue University. Conductive polymer materials were used as the primary sensing element in the sensors. Testing results reveal that embedded sensors in polymer components can successfully indicate significant signal changes more than 100 loading cycles prior to catastrophic failure. Multiple sensing methods and applications have been tested and more are being researched. These findings may open doors for future polymer sensors that can improve safety and provide useful measurements for polymer components.     

面向结构健康监测的压电传感器综述

压电传感器在结构健康监测方面的应用日益广泛。大型工程结构、混凝土结构及微电子构件的损伤监测与智能传感为其提供了广阔的应用平台。压电薄膜与涂层制备工艺不断革新,使压电传感器性能逐步优化,从而开拓了更广阔的应用领域与前景。结合国内外的研究热点和现状,简述了压电传感的动态监测原理,综合概述了外贴式压电传感、埋入式压电传感及表面涂覆式压电传感在结构智能监测中的研究进展,其中针对不同制备工艺,分别阐述了不同表面涂覆式压电传感器的应用研究,归纳并总结了3种传感器的优缺点及表面涂覆式压电传感器的制备工艺,最后展望了未来的应用前景和发展方向。