Vacuum assisted resin transfer moulding process monitoring by means of distributed fibre-optic sensors: a numerical and experimental study

A novel composite manufacturing process monitoring application using fibre-optic (FO) sensors is reported for vacuum-assisted resin transfer moulding (VaRTM) with a rigid-closed mould. A fully distributed Rayleigh-Backscattering based load-monitoring approach is demonstrated by numerical modelling and experimental application. Lateral fabric compression is reliably tracked throughout the entire VaRTM process, giving live insights on local pressure distribution, fabric stack compaction and fibre-volume fraction. These parameters have a great influence on the quality of fibre-reinforced composites and real-time tracking of them will significantly improve the quality of the manufactured part, while reducing the number of scraps and destructive testing. The final fibre volume fraction of a medium-sized plate manufactured using industrial VaRTM equipment was successfully predicted based on embedded FO sensor readings only. With a low bend-loss single mode optical fibre sensor being designed for process survivability and forming an integral part of the composite component, it enables a true entire life-cycle monitoring

Damage detection in composite skin stiffener with hybrid PZT-FO SHM system

A hybrid piezoelectric (PZT)/fibre optic diagnostic system has been developed for damage detection in built up composite structures. The hybrid system uses PZT transducers to actuate the structure and fibre optic (FO) sensors to capture the propagating wave. The diagnostic system will then have the advantages of both PZT and FO sensors. The applicability of the system is then tested for detecting an artificial damage at a skin/stiffener interface of a thick composite structure. The response of the FO sensors is then compared to PZT sensors and presented

Accuracy of distributed strain sensing with single mode fibre in composite laminates under thermal and vibration loads

In this work, the strain measurement accuracy of single-mode fibre (SMF) under thermal and vibration loads is investigated by strain-frequency shift coefficient analyses. This research allows for the application of SMF sensors for structural health monitoring in real operational conditions. The strain measurement accuracy under combined static and thermal load is investigated experimentally, which demonstrated that temperature fluctuations induce non-negligible errors in the strain measurement, even with temperature compensation applied. The temperature fluctuation range which can induce measurement errors is quantified as less than −20°C or higher than 55°C. In addition, a fatigue experiment is conducted to investigate the measurement accuracy under low-frequency vibration load. The results of the fatigue experiment demonstrate that the vibrations mainly increase the ratio of null values in strain measurements. Findings from experiments can be applied to enhance structural health monitoring accuracy and reduce false positives. This study has important implications for the service application of distributed optical fibre sensing for composite structure health monitoring

A bayesian approach for sensor optimisation in impact identification

This paper presents a Bayesian approach for optimizing the position of sensors aimed at impact identification in composite structures under operational conditions. The uncertainty in the sensor data has been represented by statistical distributions of the recorded signals. An optimisation strategy based on the genetic algorithm is proposed to find the best sensor combination aimed at locating impacts on composite structures. A Bayesian-based objective function is adopted in the optimisation procedure as an indicator of the performance of meta-models developed for different sensor combinations to locate various impact events. To represent a real structure under operational load and to increase the reliability of the Structural Health Monitoring (SHM) system, the probability of malfunctioning sensors is included in the optimisation. The reliability and the robustness of the procedure is tested with experimental and numerical examples. Finally, the proposed optimisation algorithm is applied to a composite stiffened panel for both the uniform and non-uniform probability of impact occurrence

An innovative diagnostic film for structural health monitoring of metallic and composite structures

A novel lightweight diagnostic film with sensors/actuators and a multiple-path wiring option using inkjet printing was developed. The diagnostic film allows for systematic, accurate, and repeatable sensor placement. Furthermore, the film is highly flexible and adaptable for placement on complex configurations. The film can be attached to the surface of the structure through a uniform secondary boundary procedure or embedded within the composite layup during curing. The surface-mounted film can simply be peeled off for repair or replacement without scratching or damaging the part. The film offers significant weight reduction compared to other available technologies. A set of extreme temperature, altitude, and vibration environment test profiles were carried out following the Radio Technical Commission for Aeronautics (RTCA) DO-160 document to assess the durability and performance of the diagnostic film for onboard application. The diagnostic film was shown to be durable and reliable in withstanding the variable operational and harsh environmental conditions of tests representing the conditions of regional aircraf

A smart multi-functional printed sensor for monitoring curing and damage of composite repair patch

A novel multifunctional diagnostic sensor is developed as a cost-effective, in-service structural health monitoring (SHM) system for determining the initial quality of curing of a bonded composite repair patch and assessing its long-term durability on composite structure. The proposed multi-functional sensor technology involves the creation of a "tailor-to-order" 2D conductive patterns onto step-sanded repair surface of composite repair patch using inkjet printing. In employing this methodology, bondline quality during curing and in service was successfully assessed via Impedance spectroscopy and resistance change measurements, respectively. The ability of this technology to effectively monitor the integrity of the bondline and the extent of damage in real-time was investigated by subjecting the scarf-repaired CFRP panels to 3-point bending fatigue and low-velocity impact tests. The obtained results were compared with those of transient infrared thermography (IrT) and ultrasound inspection techniques, thus validating the proposed method

Transducer placement optimisation scheme for a delay and sum damage detection algorithm

In this work, a transducer placement scheme based on wave propagation is proposed, which enhances damage localisation. The method was tailored to seek an optimal transducer network placement for a delay and sum damage detection algorithm. The proposed method determines a coverage index map and utilises a genetic algorithm to determine an optimal transducer network. It can also minimise the impact of faulty transducers, incorporate the effect of stiffeners and different damage types. The method is initially verified using numerically simulated signals. The optimal network outperformed the suboptimal for detection of holes and debonding in a stiffened panel. It is also shown that the coverage index reflected the localisation accuracy. The method is then validated with experimental results and the generated optimal transducer network compared with a suboptimal arrangement. The optimal network is shown to locate an actual crack with significantly higher accuracy than the suboptimal arrangement

Influence of composite thickness on ultrasonic guided wave propagation for damage detection

In this paper, the propagation properties of ultrasonic guided waves (UGWs) in different-thickness composites (i.e., 2, 4 and 9 mm) were critically assessed, and their effectiveness for damage detections and localisations under varying temperatures was demonstrated. A diagnostic film with phased-array lead zirconate titanate (PZT) transducers based on the ink-jet printing technique was used in the experiments. Initially, the dispersion curves for these composites were compared. Next, the effects of the composite thickness on the A0 and S0 mode amplitudes and the group velocity were investigated by active sensing. Next, the behaviours of UGWs under varying temperatures in different-thickness plates were also investigated. Finally, surface-mounted artificial damage and impact damage were detected and located in different composites

A convolutional neural network for impact detection and characterization of complex composite structures

This paper reports on a novel metamodel for impact detection, localization and characterization of complex composite structures based on Convolutional Neural Networks (CNN) and passive sensing. Methods to generate appropriate input datasets and network architectures for impact localization and characterization were proposed, investigated and optimized. The ultrasonic waves generated by external impact events and recorded by piezoelectric sensors are transferred to 2D images which are used for impact detection and characterization. The accuracy of the detection was tested on a composite fuselage panel which was shown to be over 94%. In addition, the scalability of this metamodelling technique has been investigated by training the CNN metamodels with the data from part of the stiffened panel and testing the performance on other sections with similar geometry. Impacts were detected with an accuracy of over 95%. Impact energy levels were also successfully categorized while trained at coupon level and applied to sub-components with greater complexity. These results validated the applicability of the proposed CNN-based metamodel to real-life application such as composite aircraft parts