A Comprehensive Study on Measurement Accuracy of Distributed Fiber Optic Sensors Embedded within Capillaries of Solid Structures.

Embedding fiber optic sensors (FOSs) within parts for strain measurement is attracting widespread interest due to its great potential in the field of structural health monitoring (SHM). This work proposes a novel method of embedding FOSs using capillaries within solid structures and investigates fiber positions and orientation uncertainties within capillaries of different sizes and their influences on strain measurement accuracies. To investigate how the fiber positions and orientation variations influence strain measurement accuracy, both analytical and numerical models are utilized to predict strain distributions along embedded fibers at different positions and with different orientations within the specimen. To verify the predictions, a group of specimens made of Aluminum 6082 was prepared, and the specimens in each group had capillaries of 2 mm, 4 mm, and 6 mm diameters, respectively. Fibers were embedded within each specimen using the capillaries. Four-point bending static tests were conducted for each specimen with embedded FOSs, performing in situ strain measurement. Subsequently, the specimens were partitioned into several pieces, and the cross sections were observed to know the real positions of the embedded fiber. Finally, the strain predictions at the real locations of the fiber were compared with the measured strain from the embedded FOSs. The predicted strain distributions as a function of the fiber positions alone and as a function of both the fiber positions and orientations were compared to assess the influence of fiber orientation change. The results from a combination of analytical, numerical, and experimental techniques suggest that the fiber position from the capillary center is the main factor that can influence strain measurement accuracies of embedded FOSs, and potential fiber misalignments within the capillary had a negligible influence. The fiber position-induced measured error increases from 10.5% to 18.5% as the capillary diameter increases from 2 mm to 6 mm. A 2 mm capillary diameter is able to lead to the lowest measurement error in this study and maintains ease of embedding. In addition, it is found that the measured strain always lies within a strain window defined by the strain distribution along capillary boundaries when there are no cracks. This can be further studied for crack detection.

Spectral characteristics of gold nanoparticle doped optical fibre under axial strain.

Nanoparticle (NP) doping of optical fibres can be used to increase the intensity of the backscattered light used for distributed strain sensing and has shown the advantages of high precision strain detection and multiplex sensing experimentally. However, the backscatter spectral characteristics of NP-doped optical fibres have not been described even though they are quite different from the spectra from fibre Bragg gratings (FBGs) or commercial single mode fibres. In this paper, gold NPs, used as the contrast agent in the optical fibre to increase the intensity of the backscattered light, were investigated from the aspect of their spectra. A single scattering model with Mie theory and an effective refractive index (RI) model were used to evaluate the backscattered light spectra and the Monte Carlo Method was used for seeding NPs. The results showed that the strain responsivity of gold-NP doped fibres with low volume ratio doping (single scattering restriction) are close to FBGs and commercial fibres. High volume ratios of gold NP doping increase the imaginary part of the RI of the optical fibre, which has a significant influence on the spectra in the wavenumber domain. These theoretical insights may promote the future engineering design of NP-doped fibre sensors.

Assessment of the Measurement Performance of the Multimodal Fibre Optic Shape Sensing Configuration for a Morphing Wing Section.

In this paper, with the final aim of shape sensing for a morphing aircraft wing section, a developed multimodal shape sensing system is analysed. We utilise the method of interrogating a morphing wing section based on the principles of both hybrid interferometry and Fibre Bragg Grating (FBG) spectral sensing described in our previous work. The focus of this work is to assess the measurement performance and analyse the errors in the shape sensing system. This includes an estimation of the bending and torsional deformations of an aluminium mock-up section due to static loading that imitates the behaviour of a morphing wing trailing edge. The analysis involves using a detailed calibration procedure and a multimodal sensing algorithm to measure the deflection and shape. The method described In this paper, uses a standard single core optical fibre and two grating pairs on both the top and bottom surfaces of the morphing section. A study on the fibre placement and recommendations for efficient monitoring is also included. The analysis yielded a maximum deflection sensing error of 0.7 mm for a 347 × 350 mm wing section.

A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites.

Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the static process. Thermocouples were used to measure temperature evolutions at the welding interface and within the adherends. To understand the mechanisms causing the observed temperature behaviours, the results were compared to temperature measurements from an equivalent static welding process and to the predictions from a simplified heat transfer model. Despite the significantly higher temperatures measured at the welding interface for the continuous process, viscoelastic bulk heat generation and not thermal conduction from the interface was identified as the main cause of higher through-the-thickness heating in the top adherend. Interestingly the top adherend seemed to absorb most of the vibrational energy in the continuous process as opposed to a more balanced energy share between the top and bottom adherend in the static process. Finally, the higher temperatures at the welding interface in continuous ultrasonic welding were attributed to pre-heating of the energy director due to the vibrations being transmitted downstream of the sonotrode, to reduced squeeze-flow of energy director due to the larger adherend size, and to heat flux originating downstream as the welding process continues.

Modeling and Imaging of Ultrasonic Array Inspection of Side Drilled Holes in Layered Anisotropic Media.

There has been an increase in the use of ultrasonic arrays for the detection of defects in composite structures used in the aerospace industry. The response of a defect embedded in such a medium is influenced by the inherent anisotropy of the bounding medium and the layering of the bounding medium and hence poses challenges for the interpretation of the full matrix capture (FMC) results. Modeling techniques can be used to understand and simulate the effect of the structure and the defect on the received signals. Existing modeling techniques, such as finite element methods (FEM), finite difference time domain (FDTD), and analytical solutions, are computationally inefficient or are singularly used for structures with complex geometries. In this paper, we develop a novel model based on the Gaussian-based recursive stiffness matrix approach to model the scattering from a side-drilled hole embedded in an anisotropic layered medium. The paper provides a novel method to calculate the transmission and reflection coefficients of plane waves traveling from a layered anisotropic medium into a semi-infinite anisotropic medium by combining the transfer matrix and stiffness matrix methods. The novelty of the paper is the developed model using Gaussian beams to simulate the scattering from a Side Drilled Hole (SDH) embedded in a multilayered composite laminate, which can be used in both immersion and contact setups. We describe a method to combine the scattering from defects with the model to simulate the response of a layered structure and to simulate the full matrix capture (FMC) signals that are received from an SDH embedded in a layered medium. The model-assisted correction total focusing method (MAC-TFM) imaging is used to image both the simulated and experimental results. The proposed method has been validated for both isotropic and anisotropic media by a qualitative and quantitative comparison with experimentally determined signals. The method proposed in this paper is modular, computationally inexpensive, and is in good agreement with experimentally determined signals, and it enables us to understand the effects of various parameters on the scattering of a defect embedded in a layered anisotropic medium.

Optimization of light scattering enhancement by gold nanoparticles in fused silica optical fiber.

A conventional distributed fiber optic sensing system offers close to linear sensitivity along the fiber length. However gold nanoparticles (NP) have been shown to be able to enhance the contrast ratio to improve the quality of signal detection. The challenge in improving the contrast of reflected signals is to optimise the nanoparticle doping concentration over the densed sensing length to make best use of the distributed fiber sensing hardware. In this paper, light enhancement by spherical gold NPs in the optical fibers was analyzed by considering the size-induced NP refractive index changes. This was achieved by building a new model to relate backscattered light from a gold NP suspension between the optical fiber end tips and backscattered light from gold NPs in the core of the optical fiber. The paper provides a model to determine the optimized sizes and concentrations of NPs for sensing at different desired penetration depths in the optical fiber.

A Gaussian Beam Based Recursive Stiffness Matrix Model to Simulate Ultrasonic Array Signals from Multi-Layered Media.

Ultrasonic testing using arrays is becoming widely used to test composite structures in the Aerospace industry. In recent years, the Full Matrix Capture (FMC) technique has been implemented to extract the signals for post-processing to form an image. The inherent anisotropy and the layering of the structure pose challenges for the interpretation of this FMC data. To overcome this challenge, modeling techniques are required that take into account the diffraction caused by finite-size transducers and the response of the structure to these bounded beams. Existing models either homogenize the entire structure, use computationally expensive finite difference time domain (FDTD) methods, or do not consider the shape of the bounded beam, which is used to test such structures. This paper proposes a modeling technique based on combining the Multi-Gaussian beam model with the recursive stiffness matrix method to simulate the FMC signals for layered anisotropic media. The paper provides the steps required for the modeling technique, the extraction of the system efficiency factor, and validation of the model with experimentally determined signals for aluminum as an isotropic material such as aluminum and Carbon Fiber Reinforced Plastic (CFRP) laminate as a layered material. The proposed method is computationally inexpensive, shows good agreement with the experimentally determined FMC data, and enables us to understand the effects of various transducer and material parameters on the extracted FMC signals.

Simulation of Ultrasonic Beam Propagation From Phased Arrays in Anisotropic Media Using Linearly Phased Multi-Gaussian Beams.

Phased array ultrasonic testing is widely used to test structures for flaws due to its ability to produce steered and focused beams. The inherent anisotropic nature of some materials, however, leads to skewing and distortion of the phased array beam and consequently measurement errors. To overcome this, a quantitative model of phased array beam propagation in such materials is required, so as to accurately model the skew and the distortion. The existing phased array beam models which are based on exact methods or numerical methods are computationally expensive or time consuming. This article proposes a modeling approach based on developing the linear phased multi-Gaussian beam (MGB) approach to model beam steering in anisotropic media. MGBs have the advantages of being computationally inexpensive and remaining non-singular. This article provides a comparison of the beam propagation modeled by the developed ordinary Gaussian beam and linear phased Gaussian beam models through transversely isotropic austenitic steel for different steering angles. It is shown that the linear phased Gaussian beam model outperforms the ordinary one, especially at steering angles higher than 20° in anisotropic solids. The proposed model allows us to model the beam propagation from phased arrays in both isotropic and anisotropic media in a way that is computationally inexpensive. As a further step, the developed model has been validated against a finite element model (FEM) computed using COMSOL Multiphysics.

Optical coherence elastography for measuring the deformation within glass fiber composite.

Optical coherence elastography (OCE) has been applied to the study of microscopic deformation in biological tissue under compressive stress for more than a decade. In this paper, OCE has been extended for the first time, to the best of our knowledge, to deformation measurement in a glass fiber composite in the field of nondestructive testing. A customized optical coherence tomography system, combined with a mechanical loading setup, was developed to provide pairs of prestressed and stressed structural images. The speckle tracking algorithm, based on 2D cross correlation, was used to estimate the local displacements in micrometer scale. The algorithm was first evaluated by a test of rigid body translation. Then the experiments were carried out with the tensile test and three point bending on a set of glass fiber composites. The structural features and structural variations during the mechanical loadings are clearly observed with the presented displacement maps. The advantages and prospects for OCE application on glass fiber composites are discussed at the end of this paper.