Monitoring of Composite Structures for Re-Usable Space Applications Using FBGs: The Influence of Low Earth Orbit Conditions.

Fiber Bragg grating sensors (FBGs) are promising for structural health monitoring (SHM) of composite structures in space owing to their lightweight nature, resilience to harsh environments, and immunity to electromagnetic interference. In this paper, we investigated the influence of low Earth orbit (LEO) conditions on the integrity of composite structures with embedded optical fiber sensors, specifically FBGs. The LEO conditions were simulated by subjecting carbon fiber-reinforced polymer (CFRP) coupons to 10 cycles of thermal conditioning in a vacuum (TVac). Coupons with embedded optical fibers (OFs) or capillaries were compared with reference coupons without embedded OFs or capillaries. Embedded capillaries were necessary to create in situ temperature sensors. Tensile and compression tests were performed on these coupons, and the interlaminar shear strength was determined to assess the influence of TVac conditioning on the integrity of the composite. Additionally, a visual inspection of the cross-sections was conducted. The impact on the proper functioning of the embedded FBGs was tested by comparing the reflection spectra before and after TVac conditioning and by performing tensile tests in which the strain measured using the embedded FBGs was compared with the output of reference strain sensors applied after TVac conditioning. The measured strain of the embedded FBGs showed excellent agreement with the reference sensors, and the reflection spectra did not exhibit any significant degradation. The results of the mechanical testing and visual inspection revealed no degradation of the structural integrity when comparing TVac-conditioned coupons with non-TVac-conditioned coupons of the same type. Consequently, it was concluded that TVac conditioning does not influence the functionality of the embedded FBGs or the structural integrity of the composite itself. Although in this paper FBG sensors were tested, the results can be extrapolated to other sensing techniques based on optical fibers.

Bragg-Grating-Based Photonic Strain and Temperature Sensor Foils Realized Using Imprinting and Operating at Very Near Infrared Wavelengths.

Thin and flexible sensor foils are very suitable for unobtrusive integration with mechanical structures and allow monitoring for example strain and temperature while minimally interfering with the operation of those structures. Electrical strain gages have long been used for this purpose, but optical strain sensors based on Bragg gratings are gaining importance because of their improved accuracy, insusceptibility to electromagnetic interference, and multiplexing capability, thereby drastically reducing the amount of interconnection cables required. This paper reports on thin polymer sensor foils that can be used as photonic strain gage or temperature sensors, using several Bragg grating sensors multiplexed in a single polymer waveguide. Compared to commercially available optical fibers with Bragg grating sensors, our planar approach allows fabricating multiple, closely spaced sensors in well-defined directions in the same plane realizing photonic strain gage rosettes. While most of the reported Bragg grating sensors operate around a wavelength of 1550 nm, the sensors in the current paper operate around a wavelength of 850 nm, where the material losses are the lowest. This was accomplished by imprinting gratings with pitches 280 nm, 285 nm, and 290 nm at the core-cladding interface of an imprinted single mode waveguide with cross-sectional dimensions 3 × 3 µm². We show that it is possible to realize high-quality imprinted single mode waveguides, with gratings, having only a very thin residual layer which is important to limit bend losses or cross-talk with neighboring waveguides. The strain and temperature sensitivity of the Bragg grating sensors was found to be 0.85 pm/µÎµ and -150 pm/°C, respectively. These values correspond well with those of previously reported sensors based on the same materials but operating around 1550 nm, taking into account that sensitivity scales with the wavelength.

Design and Integration of Flexible Sensor Matrix for in Situ Monitoring of Polymer Composites.

Sensory polymer composites are highly desirable for applications such as in situ and real-time production processes and structural health monitoring, and for technologies that include human-machine interfaces for the next generation of Internet of Things. However, the development of these materials is still in its infancy: these materials have been reported, but the large-scale fabrication of polymer composites with versatile and customizable sensing capabilities has yet to be demonstrated. Here, we report on a scalable fabrication strategy that enables such materials by designing and integrating PCB technology-inspired large-area flexible sensor matrices into polymer composites. The integrated sensor matrices successfully monitored in situ the production processes and structural health of an industrial polymer composite: from the application of vacuum, resin flow and polymerization, production defects, and temperature distribution. Our results demonstrate that the proposed strategy is a simple and effective solution as a distributed monitoring platform for polymer composites and shows the potential toward next generation of sensory polymer composites.

Detection, Localization and Quantification of Impact Events on a Stiffened Composite Panel with Embedded Fiber Bragg Grating Sensor Networks.

Nowadays, it is possible to manufacture smart composite materials with embedded fiber optic sensors. These sensors can be exploited during the composites' operating life to identify occurring damages such as delaminations. For composite materials adopted in the aviation and wind energy sector, delaminations are most often caused by impacts with external objects. The detection, localization and quantification of such impacts are therefore crucial for the prevention of catastrophic events. In this paper, we demonstrate the feasibility to perform impact identification in smart composite structures with embedded fiber optic sensors. For our analyses, we manufactured a carbon fiber reinforced plate in which we embedded a distributed network of fiber Bragg grating (FBG) sensors. We impacted the plate with a modal hammer and we identified the impacts by processing the FBG data with an improved fast phase correlation (FPC) algorithm in combination with a variable selective least squares (VS-LS) inverse solver approach. A total of 164 impacts distributed on 41 possible impact locations were analyzed. We compared our methodology with the traditional P-Inv based approach. In terms of impact localization, our methodology performed better in 70.7% of the cases. An improvement on the impact time domain reconstruction was achieved in 95 . 1 % of the cases.

RTM Production Monitoring of the A380 Hinge Arm Droop Nose Mechanism: A Multi-Sensor Approach.

This 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. Sensors 2015, 15 27175 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.

A micro-computed tomography technique to study the quality of fibre optics embedded in composite materials.

Quality of embedment of optical fibre sensors in carbon fibre-reinforced polymers plays an important role in the resultant properties of the composite, as well as for the correct monitoring of the structure. Therefore, availability of a tool able to check the optical fibre sensor-composite interaction becomes essential. High-resolution 3D X-ray Micro-Computed Tomography, or Micro-CT, is a relatively new non-destructive inspection technique which enables investigations of the internal structure of a sample without actually compromising its integrity. In this work the feasibility of inspecting the position, the orientation and, more generally, the quality of the embedment of an optical fibre sensor in a carbon fibre reinforced laminate at unit cell level have been proven.

Shear stress sensing with Bragg grating-based sensors in microstructured optical fibers.

We demonstrate shear stress sensing with a Bragg grating-based microstructured optical fiber sensor embedded in a single lap adhesive joint. We achieved an unprecedented shear stress sensitivity of 59.8 pm/MPa when the joint is loaded in tension. This corresponds to a shear strain sensitivity of 0.01 pm/µÎµ. We verified these results with 2D and 3D finite element modeling. A comparative FEM study with conventional highly birefringent side-hole and bow-tie fibers shows that our dedicated fiber design yields a fourfold sensitivity improvement.

Microstructured optical fiber sensors embedded in a laminate composite for smart material applications.

Fiber Bragg gratings written in highly birefringent microstructured optical fiber with a dedicated design are embedded in a composite fiber-reinforced polymer. The Bragg peak wavelength shifts are measured under controlled axial and transversal strain and during thermal cycling of the composite sample. We obtain a sensitivity to transversal strain that exceeds values reported earlier in literature by one order of magnitude. Our results evidence the relevance of using microstructured optical fibers for structural integrity monitoring of composite material structures.

Strain measurements of composite laminates with embedded fibre bragg gratings: criticism and opportunities for research.

Embedded optical fibre sensors are considered for structural health monitoring purposes in numerous applications. In fibre reinforced plastics, embedded fibre Bragg gratings are found to be one of the most popular and reliable solutions for strain monitoring. Despite of their growing popularity, users should keep in mind their shortcomings, many of which are associated with the embedding process. This review paper starts with an overview of some of the technical issues to be considered when embedding fibre optics in fibrous composite materials. Next, a monitoring scheme is introduced which shows the different steps necessary to relate the output of an embedded FBG to the strain of the structure in which it is embedded. Each step of the process has already been addressed separately in literature without considering the complete cycle, from embedding of the sensor to the internal strain measurement of the structure. This review paper summarizes the work reported in literature and tries to fit it into the big picture of internal strain measurements with embedded fibre Bragg gratings. The last part of the paper focuses on temperature compensation methods which should not be ignored in terms of in-situ measurement of strains with fibre Bragg gratings. Throughout the paper criticism is given where appropriate, which should be regarded as opportunities for future research.