基于内埋光纤Bragg光栅传感器的复合材料固化过程监测

为了全面了解复合材料的固化特性,在对碳纤维增强树脂基复合材料固化变形进行数值仿真分析的基础上,将自行设计的光纤Bragg光栅（FBG）传感器埋入复合材料中,实时在线监测复合材料固化过程中温度和应变的演变。预浸料铺层方式为[0₁₁/90₁₁],分别在层合板0°和45°方向的典型位置埋入FBG温度和应变传感器,采用热模压方式固化成型复合材料层合板,并对成型后的层合板进行连续2次降温处理,实时记录固化过程中FBG传感器中心波长的变化。结果表明:在相同的温度条件下,复合材料在第1次降温初始阶段的压应变绝对值明显小于在第2次降温初始阶段的压应变绝对值,表明复合材料在第1次降温过程中仍在进行FBG传感器可检的“后固化”反应;此外,层合板变形的FBG传感器监测数据与有限元模拟结果吻合良好。因此,采用内埋FBG传感器的方法能够实时监测复合材料固化过程,为更全面地分析复合材料固化特性提供了一种可靠有效的方法。      

Simulation of curing process of carbon/epoxy composite during autoclave degassing molding by considering phase changes of epoxy resin

Strain monitoring of a carbon/epoxy composite cross-ply laminate ([0₅/90₅]_s) during thermoforming was conducted by using fiber Bragg grating (FBG) sensors. The entire process was simulated by employing finite element analysis (FEA) by taking into consideration the phase changes of the epoxy resin. For the precise simulation of the curing process, a dielectrometry sensor was used to detect the epoxy-resin dissipation factor, which in turn was used to identify the curing point. To investigate the phase changes and consolidation of the composite laminate by employing FEA, modulus changes with temperature were measured by dynamic mechanical analysis (DMA), and the permeability was estimated by measuring the fiber volume fraction according to the curing temperature. As the epoxy resin changed from a liquid to solid phase, the strain generated along the carbon fibers dynamically changed, and the analysis results generally predicted the strain variation quite well. To apply this simulation technique to practical structures, a composite-aluminum hybrid wheel was analyzed and experimentally verified.     

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.     

Local strain in a 5-harness satin weave composite under static tension: Part I - Experimental analysis

This paper presents an experimental method for determining the local strain distribution in the plies of a thermoplastic 5-harness satin weave composite under uni-axial static tensile load. In contrast to uni-directional composites, the yarn interlacing pattern in textile composites causes heterogeneous strain fields with large strain gradients around the yarn crimp regions. In addition, depending on the local constraints that are imposed by the surrounding plies, the deformation behavior of the laminate inner layers may vary from that of the surface layers, which are relatively more free to deform, compared to the inner layers. In order to validate the above hypothesis, the local strains on the composite surface were measured using digital image correlation technique (LIMESS). Internal strains in the composite laminate were measured using embedded fibre optic sensors (FOS).Based on the DIC results, the strain profiles at various locations on the composite surface were estimated. Using the FOS results, the maximum and minimum strain values in the laminate inner layers were evaluated. Comparison of the local strain values at different laminate positions provides an estimate of the influence of the adjacent layers on the local longitudinal strain behavior of a satin weave composite. Part II of this paper elucidates the local strain variation computed using the meso-FE simulations. In addition to the comparison of numerical and experimental strain profiles, Part II presents the maximum and minimum strain envelopes for the carbon-PolyPhenelyne Sulphide (PPS) thermoplastic 5-harness satin weave composite.     

Determination of anisotropic geometrical parameters for the electrical characterization of carbon/epoxy composite during oven curing

Cure monitoring is an important tool for ensuring manufacturing reliability and reproducibility of composite parts. Among a variety of techniques, electrical measurements are used. However, electrical values are affected by cure cycles and by the rheological and geometrical parameters during curing. All these parameters must be taken into account to establish electrical models. The present paper proposes to study the changes in the geometrical parameters of an oven-cured composite made of T700/M21 prepregs during curing. For this work, microstructural analyses (in the three orthotropic planes) were carried out using specific curing, i.e. by releasing the vacuum at characteristic points (time and temperature). The following parameters were measured (manual and automatic approaches): ply, inter-plies and global thicknesses; percolation parameters; and volume and surface ratios (fibres, matrix and voids). The parameters obtained will be used in future works to define an electrical model for real-time control of the cure process.     

Measuring changing strain fields in composites with Distributed Fiber-Optic Sensing using the optical backscatter reflectometer

Background/purposeMeasurements of strains in critical components are often required in addition to finite element calculations when evaluating a structure.MethodsThis paper describes how standard optical fibers, bonded to the surface or embedded in a laminate, can measure strain fields along the entire length of the fiber, using the optical backscatter reflectometer.ResultsA strain field measurement can be much better compared to simulations than the more common single point measurements with strain gauges or Bragg Gratings. Changes of the strain field can be related to damage development and can be used for structural health monitoring. Practical aspects of using the fibers are also discussed.ConclusionDistributed Fiber-Optic Sensing was successfully embedded and bonded to a composite joint. Adhesive damage was identified and the strain field agreed well with FE-Analysis.     

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.     

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.     

光纤布拉格光栅监测复合材料固化

复合材料层合板在固化成型过程中形成的残余应变和应力是影响材料质量的重要因素,它与预浸料铺层在固化工艺过程中产生的应变密切相关。在研究和测试了光纤布拉格光栅应变和温度传感器传感特性的基础上,将二者埋入复合材料预浸料铺层,在热压釜成型工艺过程中监测了材料内部的温度和应变发展历程,由此获得对称正交层合板的宏观残余应变。监测结果表明,单向和对称正交层合板在固化结束后都将产生收缩,对称正交层合板铺层内的残余应变平行于纤维方向为压应变,垂直于纤维方向为拉应变。光纤光栅传感器为复合材料固化监测及层合板残余应力分析提供了一种新的工具,为实现复合材料从制造到服役的全寿命、一体化监测提供了可能。      

Hybrid CFRP/titanium bolted joints: Performance assessment and application to a spacecraft payload adaptor

This paper presents an experimental investigation of the mechanical response and the industrial manufacturability of CFRP–titanium hybrid laminates using the example of a spacecraft payload adaptor. The local hybridization with metal within a bolted joint region of composite laminates is proven to be an effective method of increasing the mechanical joint efficiency of highly loaded bolted joints. High-strength titanium foils are locally embedded into the composite laminate by means of ply substitution techniques, thus avoiding any local laminate thickening and providing for a local laminate with high bearing and shear capabilities. An extensive sample and component test program has been performed evaluating the impact of different design parameters and load conditions. The verification of the hybrid technique’s processability, inspectability and compatibility with a standard industrial fibre placement process has been successfully demonstrated through the manufacturing of a spacecraft payload adaptor featuring diverse applications of the hybridization technique.     

Optimization of infrared radiation cure process parameters for glass fiber reinforced polymer composites

Elevated temperature post curing is one of the most critical step in the processing of polymer composites. It ensures that the complete cross-linking takes place to produce the targeted properties of composites. In this work infrared radiation (IR) post curing process for glass fiber reinforced polymer composite laminates is studied as an alternative to conventional thermal cure. Distance from the IR source, curing schedule and volume of the composite were selected as the IR cure parameters for optimization. Design of experiments (DOE) approach was adopted for conducting the experiments. Tensile strength and flexural strength of the composite laminate were the responses measured to select the final cure parameters. Analysis of variance (ANOVA), surface plots and contour plots clearly demonstrate that the distance from the IR source and volume of the composite contribute nearly 70% to the response functions. This establishes that polymer composites cured using IR technique can achieve the same properties using only 25% of the total time compared to that of conventional thermal curing.     

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.     

Micro-mechanical finite element analysis of Z-pins under mixed-mode loading

This paper presents a three-dimensional micro-mechanical finite element (FE) modelling strategy for predicting the mixed-mode response of single Z-pins inserted in a composite laminate. The modelling approach is based upon a versatile ply-level mesh, which takes into account the significant micro-mechanical features of Z-pinned laminates. The effect of post-cure cool down is also considered in the approach. The Z-pin/laminate interface is modelled by cohesive elements and frictional contact. The progressive failure of the Z-pin is simulated considering shear-driven internal splitting, accounted for using cohesive elements, and tensile fibre failure, modelled using the Weibull’s criterion. The simulation strategy is calibrated and validated via experimental tests performed on single carbon/BMI Z-pins inserted in quasi-isotropic laminate. The effects of the bonding and friction at the Z-pin/laminate interface and the internal Z-pin splitting are discussed. The primary aim is to develop a robust numerical tool and guidelines for designing Z-pins with optimal bridging behaviour.     

Simulation of delamination–migration and core crushing in a CFRP sandwich structure

Following the onset of damage caused by an impact load on a composite laminate structure, delaminations often form propagating outwards from the point of impact and in some cases can migrate via matrix cracks between plies as they grow. The goal of the present study is to develop an accurate finite element modeling technique for simulation of the delamination–migration phenomena in laminate impact damage processes. An experiment was devised where, under a quasi-static indentation load, an embedded delamination in the facesheet of a laminate sandwich specimen migrates via a transverse matrix crack and then continues to grow on a new ply interface. Using data from this test for validation purposes, several finite element damage simulation methods were investigated. Comparing the experimental results with those of the different models reveals certain modeling features that are important to include in a numerical simulation of delamination–migration and some that may be neglected.     

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.     

A new structural health monitoring system for composite laminates

The increasing use of composite laminates in safety critical structures has prompted the development of a robust structural health monitoring system for laminates, which uses metastable ferrous alloy inserts embedded within the laminate during component construction to provide an indication of the peak tensile strain encountered by the laminate. The metastable ferrous alloy insert has an austenitic crystal structure at room temperature, but upon application of strain, this transforms to a thermodynamically stable martensite, resulting in a change in magnetic susceptibility, which can be correlated with the peak strain experienced by the material (strain memory effect). This paper presents the test results that show that it is possible to manufacture a smart laminate in this fashion, and that sufficient strain is experienced by the insert to provide a significant change in magnetic susceptibility, thereby warning of a high strain level in the laminate. Various insert geometries and laminate thicknesses are also tested for their effect on the susceptibility measurements.     

光纤传感器监测复合材料固化过程

设计了两种新型光纤传感器,一种是通过测量光纤末端近场模斑谱反映光纤埋置 脂折射率的变化,另一种行微弯衰减方法测量复合材料固化中铺层被压缩的进程。利用这两种传感器进行了复合材料固化监测实验,结果表明,发现光纤模斑传感器的信号可以反映树脂基体的粘度的变化历程,光纤微弯传感器的信号可以反映铺层被压缩的过程,监测这两个关键的参数变量不但有利于操作工艺的优化,而且为建立复合材料因化过程的智能化在线监控系统奠     

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.     

Monitoring mode II fracture behaviour of composite laminates using embedded fiber-optic sensors

Utilization of embedded Fiber Bragg Grating (FBG) sensors for monitoring mode II fracture behaviour of composite laminate beams containing different delaminations along the thickness-wise direction, by virtue of End-Notch Flexure (ENF) tests, is presented. Non-uniform strain distribution due to the stress concentration at the delamination tip was examined by the way of observing the reflection spectrum from the FBG sensor. The stress concentration in ENF specimens, which are subjected to various applied loads, was analyzed in terms of the shift, shape, bandwidth and intensity of the reflection spectrum. Relationships between the load–displacement graphs and the corresponding reflection spectra under ENF tests were established. In addition, the feasibility and reliability of using the embedded FBG sensors for mode II fracture behaviour monitoring in the composite laminates is discussed.     

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.