Flexible thin polymer waveguide Bragg grating sensor foils for strain sensing

This paper demonstrates that epoxy-based single mode polymer waveguides with Bragg gratings can be realized in very thin (down to 50 micron) polymer foils which are suitable for strain sensing when integrated inside glass fiber reinforced polymer composite materials. The single mode waveguides were fabricated using laser direct-write lithography and the gratings were realized using nanoimprint lithography. These steps were performed on a temporary rigid carrier substrate and afterwards the functional layers were released yielding the thin, flexible sensor foils which can be laser-cut to the required dimensions. The Bragg grating-based polymer waveguide sensor foils were characterized before and after embedding into the composite. As expected, there was a blue shift in the reflection spectrum because of residual strain due to the embedding process. However, the quality of the signal did not degrade after embedding, both for 50 and 100 micron thick sensor foils. Finally, the sensitivity to strain of the embedded sensors was determined using a tensile test and found to be about 1 pm / microstrain

Non-destructive evaluation of an infusion process using capacitive sensing technique

In this study, a capacitive sensing based non-destructive evaluation technique is applied to a vacuum assisted resin infusion process for the fabrication of glass fibre reinforced composites, as such different steps of the fabrication process (the injection of resin, the curing and the post curing) can be better understood to increase the quality of the fabricated part and reduce the fabrication costs. An interdigital coplanar capacitive sensor was designed, fabricated, and embedded in the glass fibre reinforced composites. Experimental data clearly shows different stages of the resin infusion process: wetting of the glass fibres marked by rapid increase of capacitance; domination of ionic conduction at the early stage of the cure when the resin is still in a liquid state; the vitrification point, indicating a transition of the resin from a gelly state to a glassy state, marked by the relatively big decrease in capacitance; further polymerization during post-curing, marked by a peak in capacitance at the beginning of post-curing cycle, and finally the completion of the cure marked by the saturation of capacitance to a final value. The different phenomena observed during the experiment can be used as a tool for in situ on-line monitoring of composites cure

Deformable microsystem for in situ cure degree monitoring of GFRP(Glass Fibre Reinforced Plastic)

Fibre Reinforced Polymer (FRP) is becoming a valid alternative to many traditional heavy metal industries because of its high specific stiffness over the more classical construction metals. Recent trend of more complex geometry of composites is causing increasing difficulty in composite manufacturing. A method to optimize the manufacturing process is thus imposed to ensure and improve the quality of manufactured parts. Because of the irregular 3D shapes of the composites, traditional flat sensor system is becoming unfavorable and nonpractical for monitoring purpose. In this work, the current development status of a deformable microsystem for in situ cure degree monitoring of a glass fibre reinforced plastic is presented. To accommodate the non-flat shape of the composites, the proposal is to interconnect non-deformable functional island, which contains the capacitive sensor for cure degree monitoring, with meander-shaped deformable interconnections. The developed sensor system is able to withstand the manufacturing process where change of pressure and internal strain, thus force exerted on the sensor system, is involved

RTM production monitoring of the A380 hinge arm droop nose mechanism: a multi-sensor approach

his research presents a case study of production monitoring on an aerospace composite component: the hinge arm of the droop nose mechanism on the Airbus A380 wing leading edge. A sensor network composed of Fibre Bragg Gratings, capacitive sensors for cure monitoring and thermocouples was embedded in its fibre reinforced lay-up and measurements were acquired throughout its Resin Transfer Moulding production process. Two main challenges had to be overcome: first, the integration of the sensor lines in the existing Resin Transfer Moulding mould without modifying it; second, the demoulding of the component without damaging the sensor lines. The proposed embedding solution has proved successful. The wavelength shifts of the Fibre Bragg Gratings were observed from the initial production stages, over the resin injection, the complete curing of the resin and the cooling-down prior to demoulding. The sensors proved to be sensitive to detecting the resin flow front, vacuum and pressure increase into the mould and the temperature increase caused by the resin curing. Measurements were also acquired during the post-curing cycle. Residual strains during all steps of the process were derived from the sensors’ wavelength shift, showing values up to 0.2% in compression. Moreover, the capacitive sensors were able to follow-up the curing degree during the production process. The sensors proved able to detect the resin flow front, whereas thermocouples could not measure an appreciable increase of temperature due to the fact that the resin had the same temperature as the mould

Dynamic strain measurements on automotive and aeronautic composite components by means of embedded fiber bragg grating sensors

The measurement of the internal deformations occurring in real-life composite components is a very challenging task, especially for those components that are rather difficult to access. Optical fiber sensors can overcome such a problem, since they can be embedded in the composite materials and serve as in situ sensors. In this article, embedded optical fiber Bragg grating (FBG) sensors are used to analyze the vibration characteristics of two real-life composite components. The first component is a carbon fiber-reinforced polymer automotive control arm; the second is a glass fiber-reinforced polymer aeronautic hinge arm. The modal parameters of both components were estimated by processing the FBG signals with two interrogation techniques: the maximum detection and fast phase correlation algorithms were employed for the demodulation of the FBG signals; the Peak-Picking and PolyMax techniques were instead used for the parameter estimation. To validate the FBG outcomes, reference measurements were performed by means of a laser Doppler vibrometer. The analysis of the results showed that the FBG sensing capabilities were enhanced when the recently-introduced fast phase correlation algorithm was combined with the state-of-the-art PolyMax estimator curve fitting method. In this case, the FBGs provided the most accurate results, i.e., it was possible to fully characterize the vibration behavior of both composite components. When using more traditional interrogation algorithms (maximum detection) and modal parameter estimation techniques (Peak-Picking), some of the modes were not successfully identified

Micro-CT as a well-established technique to investigate the internal damage state of a composite laminate subjected to fatigue

Micro Computed Tomography (micro-CT) has become an established non-destructive technique for microstructure investigation of composite materials, where due to the intrinsic difficulty in defining suitable damage models, it can be proved useful as such in helping to interpret and validate them. In this study the evolution of damage on several cross-ply laminates having embedded fibre optics of different diameters was investigated over several millions of fatigue cycles. High-resolution 3D X-ray tomography has been performed at different intervals in the vicinity of the sensor and damage has been quantified by counting the overall number of matrix cracks in the scanned volume. A clear evolution of damage has been noticed in accordance with a measured stiffness degradation of the laminate. Nevertheless, the results reveal that for the given loading conditions damage is not evolving in the vicinity of the fibre optics