Health monitoring of marine composite structural joints using fibre optic sensors

This paper describes a methodology for the health monitoring of composite marine joint structures based on strain measurements under operational loading using embedded fibre Bragg grating sensors. Finite element modelling indicated that the presence of a disbond significantly altered the bond-line longitudinal strain distribution. This was verified qualitatively through an experimental test program. The experimental results are examined in relation to the FE predictions and the implications for a practical strain-based SHM system are discussed. A technique is developed, based on novel signal processing and statistical outlier detection. This enables the sensor measurements to be used for damage detection without reference to a high-fidelity numerical model of the structure which is often difficult and resource-intensive to generate. The technique is shown to provide successful damage diagnoses with an acceptable level of accuracy. Further improvement in diagnostic accuracy may be achieved by increasing the sensor density.     

Ultrasonic inspection of adhesively bonded CFRP/aluminum joints using pulsed laser scanning

In this study, we propose an ultrasonic inspection technique for detecting disbonds in adhesively bonded carbon fiber-reinforced plastics (CFRP)/aluminum joints using pulsed laser scanning. A specimen with artificially induced square disbonds was scanned by a pulsed laser for ultrasound generation, and the propagating waves were received by a transducer placed on its surface. A series of images of the traveling waves were obtained by processing the received signals. An initial, quick inspection was performed using low-frequency Lamb waves. Changes in the propagation of the Lamb waves were observed at the disbond regions, and disbonds larger than 5 × 5 mm² were successfully detected. A second, detailed inspection of the detected disbond regions was performed using the high-frequency through-transmission ultrasonic method. The shape of the disbond was precisely imaged, and the evaluated size of the disbond matched well with the actual size. We thus demonstrated the efficiency and the feasibility of the proposed technique for the inspection of adhesively bonded CFRP/Al joints.     

Experimental deformation analysis of an adhesively bonded multi-material joint for marine applications

The strength and deformation of full-scale adhesively bonded multi-material joints is studied in this paper. Four joints with a thick layer of methyl methacrylate adhesive (MMA) have been manufactured in shipyard conditions. In two specimens, cracks have been introduced at steel–adhesive and composite–adhesive interfaces. One cracked and one un-cracked specimen were subjected to quasi-static tensile testing; the two remaining specimens were stepwise loaded/unloaded with increasing load until failure. The strain in the adhesive layers was measured with digital image correlation (DIC). This showed a predominant shear deformation and dissimilar shear strain patterns for different bond lines. Fibre Bragg (FBG) sensors were used to monitor strains at steel and composite constituents and to detect the onset and evolution of damage in the un-cracked specimen. Strains measured by FBG sensors correspond well with DIC results at nearby regions. All specimens failed by delamination of the composite panel near the composite–adhesive interface.     

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.     

Strength and damage tolerance of composite–composite joints with steel and titanium through the thickness reinforcements

Today’s aeronautic, automotive and marine industry is in demand of structurally efficient, low weight alternatives for composite–composite joints which combine the advantages of low weight input of adhesively bonded joints and high damage tolerance of through the thickness bolted joints. In the present work, composite–composite joints are reinforced through the thickness by thin metal inserts carrying cold metal transfer welded pins (CMT pins). The influence of pin alignment and type of pin on the damage tolerance of single lap shear (SLS) composite–composite joints is investigated. The use of titanium reinforcements is evaluated and compared to stainless steel reinforced, adhesively bonded and co-cured specimens. A detailed analysis of the stress–strain behavior is given and the stiffness and energy absorption of the SLS joints during tensile loading is assessed. The results show that joints reinforced with CMT pins absorb significantly higher amounts of energy, when compared to adhesively bonded and co-cured joints.     

用于钢筋混凝土梁的光纤光栅应变传感器

在变形测定器中,光纤Bragg光栅被粘贴于内管的两端,这两端的距离确定了传感器的量规长度。为了测量拉应变和压应变,该光纤光栅必须保持处于与可能的最大压应变相等的永久性拉应变。将光纤Bragg光栅贴于H154梁的混凝土表面和H158梁的钢筋表面,以分别检测拉应变和压应变。当钢筋混凝土梁受到千斤顶的加载时,它的应变可由光纤Bragg光栅的反射Bragg波长的偏移量获得。实验表明,作为一种绝对检测器件,光纤Bragg光栅为钢筋混凝土梁提供了有效监测,其中,拉应变~1000me,而压应变~1500me。     

Life cycle monitoring and advanced quality assurance of L-shaped composite corner part using embedded fiber-optic sensor

L-shaped composite parts are structural key elements in complex-shaped aerospace composite structures, and life cycle cross-sectional strain change is their key. This study developed a fiber-optic-based life cycle monitoring system for L-shaped corner parts. A fiber Bragg grating (FBG) sensor was embedded in the through-thickness center of a corner part and the cross-sectional strain change was continuously evaluated by using a birefringence effect of the FBG. The embedded sensor could capture key strain changes throughout the structural life cycle, confirming that “non-axisymmetric strain” of the FBG sensor is a good indicator for spring-in distortion in manufacturing and through-thickness tensile failure in operation. The developed system was further utilized for advanced quality assurance of assembled L-shaped parts, and a new strength prediction method was proposed based on the FBG response. The monitoring system developed can provide a deep insight about the current internal state of L-shaped parts, and the information obtained is highly valuable for improving the design/manufacturing and for diagnosing the structural health.     

Mixed-mode delamination fracture in laminated composites

Quasi-static fracture of laminated composite plates with circular or elliptic delaminations due to transverse shear stresses is considered. The system is modeled as two laminated plates bonded everywhere except over the area of the disbond. A laminated plate theory with the effects of surface tractions and shear deformations is used for each plate and the problem is reduced to a set of integral equations. Because of the nature of the model, stress singularities along the disbond periphery appear as concentrated line forces, which are different from those obtained from three-dimensional elasticity analysis. Physically meaningful quantities such as strain energy release rates for mode I, II and III types of deformation are evaluated. Failure loads for catastrophic fracture are computed based on firstly a point criterion and secondly a physically realistic growth pattern. Results are compared with test data for disbonds located in the midplane. For such disbonds the mode I component of energy release rate is absent and, therefore, fracture is due to mode II and III interactions.     

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.     

Multiplexed Fiber Bragg Grating Interrogation System Using a Microelectromechanical Fabry–Perot Tunable Filter

This paper describes a fiber Bragg grating strain sensor interrogation system based on a microelectromechanical systems tunable Fabry–Perot filter. The shift in the Bragg wavelength due to strain applied to a sensor fiber is detected by means of a correlation algorithm which was implemented on an embedded digital signal processor. The instrument has a 70 nm tuning range, allowing multiple strain sensors to be multiplexed on the same fiber. The performance of the interrogator was characterized using an optical fiber containing six grating strain sensors embedded in a fiberglass test specimen. The measured root mean square (RMS) strain error was 1.5 microstrain, corresponding to a 1.2 pm RMS error in the estimated wavelength shift. Strain measurements are produced with an update rate of 39 samples/s.      

搭接长度和铺层方式对CFRP复合材料层合板胶接结构连接性能和损伤行为的影响

针对不同搭接长度和铺层方式的碳纤维增强树脂（CFRP）复合材料层合板单搭胶接结构进行了拉伸试验,观察了试件的受力过程和失效形态,获得了载荷-位移曲线;同时基于连续损伤力学模型和三维Hashin失效准则模拟了CFRP复合材料层合板的层内损伤形成和演化,并利用内聚力模型来模拟层间及胶层的失效损伤,对CFRP复合材料层合板单搭胶接结构在拉伸作用下的失效强度和损伤机制进行了预测,通过对比验证了该数值方法的有效性;通过数值试验比较不同搭接长度和铺层方式的单搭胶接结构及双搭胶接结构的连接强度和损伤行为,并提出了一种优化的CFRP复合材料层合板胶接结构。结果表明:CFRP复合材料层合板胶接结构的极限失效载荷随着搭接长度的增大逐渐增加并趋于稳定值,且结构的失效形式逐渐从胶层自身剪切失效过渡到邻近胶层的层合板层间分层失效;CFRP复合材料层合板胶接结构的连接强度和损伤行为随着铺层方式的不同而改变,通过对3种铺层方式的对比和分析,得到性能最好的铺层方式是[0₃/90₃]_2S;在搭接长度为5~20 mm时,通过对搭接长度进行优化,得到单搭胶接结构的最优搭接长度是17 mm,双搭胶接结构的最优搭接长度是19.3 mm,与搭接长度为20 mm相比,单搭胶接结构和双搭胶接结构的连接强度分别提高了13.26%和0.43%。      

Plasticity induced crack closure in adhesively bonded joints under fatigue loading

The mean load of a cyclic loading has a large effect on fatigue crack growth rates in metallic materials and bonded joints. In metallic structures, this effect has been attributed to plasticity-induced crack closure, but little is known about the mechanism responsible for this mean load effect on fatigue crack growth in adhesively bonded joints. This paper presents a computational investigation of the plasticity-induced crack closure mechanism affecting disbond growth in adhesively bonded joints under fatigue loading. The results show that the ratios of crack-opening and crack-closure are approximately independent of the level of plastic constraint, indicated by the ratio between the plastic zone size and the adhesive thickness. An effective strain-energy release rate parameter, which accounts for the crack closure behaviour, has been developed as a new correlating parameter for disbond growth. Comparisons with the experimental results pertinent to four different adhesive bonded joints reveal that this new correlating parameter is capable of unifying the fatigue growth rates by eliminating the effect of mean loads.     

Geometry and damage effects in a composite marine T-joint

The structural integrity and damage tolerance of typical composite T-joints found in ships constructed from glass fibre reinforced plastic was the subject of this investigation. The effect of the geometry of the T-joint on the strain distribution was investigated using finite element (FE) analysis. The results, reported in this paper, showed that the critical strains were significantly affected by the joint geometry. Results of the FE analysis conducted to investigate the effect of disbonds between the filler and overlaminate are also reported. This showed that particular defects led to large changes in the strains in the T-joint structure, which would encourage disbond progression. The FE model was validated by mechanical tests on a representative T-joint, instrumented with surface strain gauges and displacement transducers, into which a range of defects was progressively introduced.     

Intracore fiber bragg gratings for strain measurement in embedded composite structures

An intracore Bragg grating written on a photosensitive fiber core is used for strain measurement in composite specimens under load. The strain information is directly related to the absolute change in the Bragg-reflected wavelength. Fiber Bragg grating (FBG) sensors (fibers with intracore gratings) are thus sensitive to strain that is caused by changes in temperature as well as to load-induced changes. Thus these sensors can be made to be independent of source intensity variations and losses. FBG sensors used for load-induced strain sensing in composite structures and the effects of temperature on them are discussed. A detailed account of the use of such embedded structures as self-monitoring nondestructive testing devices is given.     

Non-destructive testing of structural composites and adhesively bonded composite joints: pulsed thermography

Structural adhesive bonding is an enabling technology for the implementation of composite assemblies in automotive applications. Therefore, the quality and reliability of the composite bond must be assured. An advanced thermal non-destructive test (NDT) method, pulsed thermography, was evaluated for its capability to assess joint quality in an adhesively bonded composite pickup truck box. Pulsed thermography, used under in-plant, pre-production conditions as would exist during process start-up and optimization trials, was shown effective in determining both the quality of the structural adhesive bonds and the quality of the composite itself. With one exception, NDT showed that bonding was performed correctly, i.e. the bond was continuous and properly placed. The exception was a ‘starved’ bond-line that we believe exists due to poor fixturing at that location. Pulsed thermography illustrated the effects of environmental and mechanical exposure on the bonded joints. Finally, the NDT method was able to show mechanical damage to the composite itself, identifying impact damage not visible to the unaided eye.     

Identification of crack and disbond fronts in repaired aircraft structural panels with bonded FRP composite patches

Structural health monitoring of fatigue-cracked aircraft structural panels repaired with bonded FRP composite patches for extending the service life of aging aircraft has received wide attention. In this paper a method for identifying the locations and shapes of crack and disbond fronts in aircraft structural panels repaired with bonded FRP composite patches is presented. The identification is performed by minimizing the residual norm between the measured in-plane strain range on a strain measurement plane in the FRP composite patches and the calculated in-plane strain range. Several numerical examples of identification of the locations and shapes of crack and disbond fronts are examined. The effects of the number of strain measurement points, position of the strain measurement plane, and measurement errors of the in-plane strain ranges on the identification results are discussed. The validity of this identification method is verified by comparing the identification results with the exact ones.     

Progressive damage and nonlinear analysis of pultruded composite structures

This study combines a simple damage modeling approach with micromechanical models for the progressive damage analysis of pultruded composite materials and structures. Two micromodels are used to generate the nonlinear effective response of a pultruded composite system made up from two alternating layers reinforced with roving and continuous filaments mat (CFM). The layers have E-glass fiber and vinylester matrix constituents. The proposed constitutive and damage framework is integrated within a finite element (FE) code for a general nonlinear analysis of pultruded composite structures using layered shell or plate elements. The micromechanical models are implemented at the through-thickness Gaussian integration points of the pultruded cross-section. A layer-wise damage analysis approach is proposed. The Tsai–Wu failure criterion is calibrated separately for the CFM and roving layers using ultimate stress values from off-axis pultruded coupons under uniaxial loading. Once a failure is detected in one of the layers, the micromodel of that layer is no longer used. Instead, an elastic degrading material model is activated for the failed layer to simulate the post-ultimate response. Damage variables for in-plane modes of failure are considered in the effective anisotropic strain energy density of the layer. The degraded secant stiffness is used in the FE analysis. Examples of progressive damage analysis are carried out for notched plates under compression and tension, and a single-bolted connection under tension. Good agreement is shown when comparing the experimental results and the FE models that incorporate the combined micromechanical and damage models.     

基于遗传算法的碳纤维增强树脂复合材料层合板单搭胶接结构的多目标优化

基于遗传算法对碳纤维增强树脂复合材料(CFRP)层合板单搭胶接结构进行了多目标优化,以提高其结构性能.首先,通过三维Hashin准则和三角形内聚力模型建立三维有限元模型来预测CFRP层内损伤过程、层间失效和胶层损伤过程,并通过试验验证其有效性.其次,利用拉丁超立方抽样(LHS)方法和二次多项式响应面法(RSM),基于搭...     

热残余应力对内埋光纤光栅传感器性能的影响

将布拉格光纤光栅(FBG)埋植于复合材料T型加筋板结构非干涉区—三角填充区作为应变传感器对复合材料加筋板在固化过程及冲击后压缩过程中的应变变化进行监测。对比了光纤刻栅区采用UV光固化树脂涂层保护和未保护的两种FBG传感器的波谱信号变化; 分析了复合材料在固化成型过程中产生的非轴对称热残余应力对FBG传感性能的影响。结果表明, 刻栅区采用聚合物涂层保护的FBG传感器的半峰宽(FWHM)在固化过程中未发生变化, 并且聚合物涂层可以有效地消除非轴对称热残余应力对光纤光栅反射波谱的影响。在冲击后压缩过程中, 采用聚合物涂层保护的FBG传感器测得的应变与贴于试样表面的应变片测得的应变数据一致性较好。本文对埋植于复合材料加筋板三角填充区的FBG传感器在复合材料固化过程及冲击后压缩过程中应变监测的有效性及可靠性进行了有益的探索。     

Crack tip identification with long FBG sensors in mixed-mode delamination

The uncertainty of the crack tip position inside composite coupons during a delamination test under variable fracture mode conditions reduces the accuracy of the experimental results. In this work a method is presented where the crack tip position is located using long embedded Fibre Bragg Grating (FBG) sensors together with the Optical Low Coherence Reflectometry (OLCR) technique. With this technique the local Bragg wavelength is measured which then enables to calculate the axial strain profile within the grating. Carbon/epoxy samples are tested under different mode ratios through the standard Mixed-Mode Bending (MMB) test. Embedded long FBG sensors are used to measure the axial strain profile along the whole grating at different stages of the test. The crack tip can be precisely identified with the long embedded FBGs and then checked by means of a visual inspection after complete delamination of the sample. The data indicate that the long FBG sensor detects the crack tip inside the sample at least as precisely as the traditionally performed visual inspections carried out during the test by means of the lateral markings. Numerical simulations using cohesive elements are in good agreement with the experimental data.