Remote Strain Sensing of CFRP Using Microwave Frequency Domain Reflectometry

NASA's Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave Frequency Domain Reflectometry (FDR) is being investigated as a method of enabling rapid remote measurement of strain occurring at the first ply of a composite fiber reinforced polymer (CFRP) structure using Radio Frequency (RF) Electro-Magnetic (EM) radiation. While microwave reflectometry has been used to detect disbonds in CFRP structures, its use in detecting strain has been limited. This work will present data demonstrating the measurement of the reactance changes due to loading conditions that are indicative of strain in a CFRP structure. In addition, the basic EM signature will be presented along with an analysis of temperature and humidity effects

Development of active microwave thermography for structural health monitoring

Active Microwave Thermography (AMT) is an integrated nondestructive testing and evaluation (NDT&E) method that incorporates aspects of microwave NDT and thermography techniques. AMT uses a microwave excitation to generate heat and the surface thermal profile of the material or structure under test is subsequently measured using a thermal camera (or IR camera). Utilizing a microwave heat excitation provides advantages over traditional thermal excitations (heat lamps, etc.) including the potential for non-contact, selective and focused heating. During an AMT inspection, two heating mechanisms are possible, referred to as dielectric and induction heating. Dielectric heating occurs as a result of the interaction of microwave energy with lossy dielectric materials which results in dissipated microwave energy and a subsequent increase in temperature. Induction heating is a result of induced surface current on conductive materials with finite conductivity under microwave illumination and subsequently ohmic loss. Due to the unique properties of microwave signals including frequency of operation, power level, and polarization, as well as their interaction with different materials, AMT has strong potential for application in various industries including infrastructure, transportation, aerospace, etc. As such, this Dissertation explores the application of AMT to NDT&E needs in these important industries, including detection and evaluation of defects in single- or multi-layered fiber-reinforced polymer-strengthened cement-based materials, evaluation of steel fiber percentage and distributions in steel fiber reinforced structures, characterization of corrosion ratio on corroded reinforcing steel bars (rebar), and evaluation of covered surface cracks orientation and size in metal structures --Abstract, page iv

Microwave NDT&E using open-ended waveguide probe for multilayered structures

Ph. D. Thesis.Microwave NDT&E has been proved to be suitable for inspecting of dielectric structures due to low attenuation in dielectric materials and free-space. However, the microwave responses from multilayered structures are complex as an interrogation of scattering electromagnetic waves among the layers and defects. In many practical applications, electromagnetic analysis based on analytic- and forward structural models cannot be generalised since the defect shape and properties are usually unknown and hidden beneath the surface layer. This research proposes the design and implementation of microwave NDT&E system for inspection of multilayered structures. Standard microwave open-ended rectangular waveguides in X, Ku and K bands (frequency range between 8-26.5 GHz) and vector network analyser (VNA) generating sweep frequency of wideband monochromatic waves have been used to obtain reflection coefficient responses over three types of challenging multilayered samples: (1) corrosion progression under coating, (2) woven carbon fibre reinforced polymer (CFRP) with impact damages, and (3) thermal coated glass fibre reinforced polymer (GFRP) pipe with inner flat-bottom holes. The obtained data are analysed by the selected feature extraction method extracting informative features and verify with the sample parameters (defect parameters). In addition, visualisation methods are utilised to improve the presentation of the defects and material structures resulting in a better interpretation for quantitative evaluation. The contributions of this project are summarised as follows: (1) implementation of microwave NDT&E scanning system using open-ended waveguide with the highest resolution of 0.1mm x 0.1 mm, based on the NDT applications for the three aforementioned samples; (2) corrosion stages of steel corrosion under coating have been successfully characterised by the principal component analysis (PCA) method; (3) A frequency selective based PCA feature has been used to visualise the impact damage at different impact energies with elimination of woven texture influences; (4) PCA and SAR (synthetic aperture radar) tomography together with time-offlight extraction, have been used for detection and quantitative evaluation of flat-bottom hole defects (i.e., location, size and depth). The results conclude that the proposed microwave NDT&E system can be used for detection and evaluation of multilayered structures, which its major contributions are follows. (1) The early stages (0-12month) of steel corrosion undercoating has been successfully characterised by mean of spectral responses from microwave opened rectangular waveguide probe and PCA. (2) The detection of low energy impact damages on CFRP as low as 4 Joules has been archived with microwave opened rectangular waveguide probe raster scan together with SAR imaging and PCA for feature extraction methods. (3) The inner flat-bottom holes beneath the thermal coated GFRP up to 11.5 mm depth has been successfully quantitative evaluated by open-ended waveguide raster scan using PCA and 3-D reconstruction based on SAR tomography techniques. The evaluation includes location, sizing and depth. Nevertheless, the major downside of feature quantities extracted from statistically based methods such as PCA, is it intensely relies on the correlation of the input dataset, and thus hardly link them with the physical parameters of the test sample, in particular, the complex composite architectures. Therefore, there are still challenges of feature extraction and quantitative evaluation to accurately determine the essential parameters from the samples. This can be achieved by a future investigation of multiple features fusion and complementary features.Ministry of Science and Technology of Royal Thai Government and Office of Educational Affairs, the Royal Thai Embass

Advanced microwave embedded sensors for infrastructure health monitoring

Microwave sensor systems have been widely investigated for many applications due to their ability to provide non-destructive, noncontact, one-sided and wireless testing. Among these applications infrastructure health monitoring of bridges, building, and dams using microwave sensors, which are mounted on or embedded in composite structures of infrastructure has been attracting an increasing interest. One of the current needs of infrastructure health monitoring includes the detection and monitoring of disbonding and gaps in concrete-based structures, which are also required for simultaneous characterization of concrete. A recently proposed microwave sensor technique exploiting a relatively simple waveguide sensor embedded in a concrete-metal structure such as a concrete-filled steel tube exhibited great potential. However, it suffers from a few drawbacks that need to be solved. This thesis aims to develop and investigate advanced microwave embedded sensors to solve main problems in the current microwave sensory technique including characterization of concrete in concrete-based structures at different stage of its life, size of the interface under inspection, detection and monitoring of a small gap between concrete and dielectric material surfaces and sensitivity to gaps. To achieve this aim the following five research contributions have been made: The first contribution is the methodology for the determination of the complex dielectric permittivity of concrete using both measurement data and simulation results at different stages (fresh, early-aged and dry) of its life. Firstly, it is developed and tested for a single flanged open-ended waveguide sensor with a hardened concrete specimen, and then the methodology is modified for the developed sensors embedded in concrete-based composite structures with fresh, early-age and dry concrete. Modern computational tool CST Microwave Studio and a performance network analyser are used for simulation and measurement, respectively, throughout this research work. The second contribution is a dual waveguide sensor, which is proposed, designed and applied for the detection and monitoring of a small gap in concrete-metal composite structures. It consists of two waveguide sections and a metal plate and uses the transmission of electromagnetic waves along gap when it occurs between the metal plate and concrete surfaces. It provides more measurement data than the single waveguide sensor for characterising concrete-metal structures such as transmission properties of guided waves along the gap and reflection properties of the metal–concrete interface at two different places at the same stage of concrete. As a result, the proposed sensor increases the size of the interface under inspection and sensitivity to the gap using the magnitude of reflection coefficient and magnitude of transmission coefficient together and/or independently. The third contribution is the design and application of a dual waveguide sensor with rectangular dielectric insertions that is proposed and tested for the characterisation of concrete–metal structures at different stages of the concrete life including its fresh stage. The dielectric insertions are designed and implanted in the waveguide sections in such a way that they create the resonant response of the sensor and prevent water and concrete entering the sections. The resonant properties of the sensor allow long-term monitoring of the concrete hydration, including the detection of the transition from fresh to hardened concrete on its first day. The proposed sensor along with the modified algorithm provides the determination of the complex dielectric permittivity of fresh concrete. The fourth contribution is a dual waveguide sensor with tapered dielectric insertions. Each tapered dielectric insertion is designed with a tapered part and rectangular part to reduce wave reflection from the insertions over an entire frequency band. The proposed sensor has improved performance at the resonant responses of a quarter-wavelength resonator formed by an open end at the tapered part and shorted end at the rectangular part of each insertion. The last contribution is the development of dual waveguide sensors with attached dielectric layer and their application for the detection and monitoring of gap between dielectric materials and concrete in metal-dielectric layer-concrete composites as well as the determination of complex dielectric permittivity of concrete at different stages of its life. One of the most attractive designs is the sensor with empty waveguide sections due to its simplicity and robustness, and capability of the layer for preventing penetration of the obstacles and water, and for optimization of the sensor. On the other hand, the sensors with dielectric insertions and the layer demonstrate a significantly higher magnitude of transmission coefficient. The proposed DWSs can be applied to characterise fresh concrete in a dielectric mould or on-line, and to investigate the shrinkage of different categories of concrete

Microwave material characterization of alkali-silica reaction (ASR) gel in cementitious materials

Since alkali-silica reaction (ASR) was recognized as a durability challenge in cement-based materials over 70 years ago, numerous methods have been utilized to prevent, detect, and mitigate this issue. However, quantifying the amount of produced ASR byproducts (i.e., ASR gel) in-service is still of great interest in the infrastructure industry. The overarching objective of this dissertation is to bring a new understanding to the fundamentals of ASR formation from a microwave dielectric property characterization point-of-view, and more importantly, to investigate the potential for devising a microwave nondestructive testing approach for ASR gel detection and evaluation. To this end, a comprehensive dielectric mixing model was developed with the potential for predicting the effective dielectric constant of mortar samples with and without the presence of ASR gel. To provide pertinent inputs to the model, critical factors on the influence of ASR gel formation on dielectric and reflection properties of several mortar samples were investigated at R, S, and X-band. Effects of humidity, alkali content, and long-term curing conditions on ASR-prone mortars were also investigated. Additionally, dielectric properties of chemically different synthetic ASR gel were also determined. All of these, collectively, served as critical inputs to the mixing model. The resulting developed dielectric mixing model has the potential to be further utilized to quantify the amount of produced ASR gel in cement-based materials. This methodology, once becomes more mature, will bring new insight to the ASR reaction, allowing for advancements in design, detection and mitigation of ASR, and eventually has the potential to become a method-of-choice for in-situ infrastructure health-monitoring of existing structures --Abstract, page v