An Efficient Procedure for Bonding Piezoelectric Transducers to Thermoplastic Composite Structures for SHM Application and Its Durability in Aeronautical Environmental Conditions.

Piezoceramic transducers (PCTs) bonded to carbon fiber-reinforced plastic (CFRP) composite structures must be durable as well as remain properly bonded to the structure in order to provide reliable data for accurate guided-wave-based structural health monitoring (SHM) of aeronautical components. The current method of bonding transducers to composite structures through epoxy adhesives faces some shortcomings, such as difficult reparability, lack of weldability, longer curing cycles, and shorter shelf life. To overcome these shortcomings, a new efficient procedure for bonding the transducers to thermoplastic (TP) composite structures was developed by utilizing TP adhesive films. Application-suitable TP films (TPFs) were identified and characterized through standard differential scanning calorimetry (DSC) and single lap shear (SLS) tests to study their melting behavior and bonding strength, respectively. Special PCTs called acousto-ultrasonic composite transducers (AUCTs) were bonded to high-performance TP composites (carbon fiber Poly-Ether-Ether-Ketone) coupons with a reference adhesive (Loctite EA 9695) and the selected TPFs. The integrity and durability of the bonded AUCTs in aeronautical operational environmental conditions (AOEC) were assessed in accordance to the standard Radio Technical Commission for Aeronautics DO-160. The AOEC tests performed were operating low and high temperatures, thermal cycling, hot-wet, and fluid susceptibility tests. The health and bonding quality of the AUCTs were evaluated by the electro-mechanical impedance (EMI) spectroscopy method and ultrasonic inspections. The AUCT defects were created artificially and their influence on the susceptance spectra (SS) was measured to compare them with the AOEC-tested AUCTs. The results show that a small change occurred in the SS characteristics of the bonded AUCTs in all of the adhesive cases after the AOEC tests. After comparing the changes in SS characteristics of simulated defects with that of the AOEC-tested AUCTs, the change is relatively smaller and therefore it can be concluded that no serious degradation of the AUCT or the adhesive layer has occurred. It was observed that the most critical tests among the AOEC tests are the fluid susceptibility tests, which can cause the biggest change in the SS characteristics. Comparing the performance of the AUCTs bonded with the reference adhesive and the selected TPFs in the AOEC tests, it was seen that some of the TPFs, e.g., Pontacol 22.100 outperforms the reference adhesive, while the other TPFs have similar performance to that of the reference adhesive. Therefore, in conclusion, the AUCTs bonded with the selected TPFs can withstand the operational and environmental conditions of an aircraft structure, and hence, the proposed procedure is easily installed, reparable, and a more reliable method of bonding sensors to aircraft structures.

Structure-Integrated Thin-Film Supercapacitor as a Sensor.

Today, aircraft composite structures are generally over-dimensioned to avoid catastrophic failure by unseen damages. This leads to a higher system weight and therefore an unwanted increase in greenhouse gas emissions. To reduce this parasitic mass, load monitoring can play an important role in damage detection. Additionally, the weight and volume of future aircraft structures can also be reduced by energy storing and load carrying structures: so-called power composites. In this study a novel method of combining both approaches for maximum weight reduction is shown. This is achieved by using power composites as load monitoring sensors and energy suppliers. Therefore, supercapacitors are integrated into fiber reinforced polymers and are then used to investigate the mechanical load influence. By using four-point bending experiments and in situ electrochemical impedance spectroscopy, a strong relation between the mechanical load and the electrochemical system is found and analyzed using a model. For the first time, it is possible to detect small strain values down to 0.2% with a power composite. This strain is considerably lower than the conventional system load. The developed model and the impedance data indicate the possibility of using the composite as an energy storage as well as a strain sensor.

Multifunctional Hybrid Fiber Composites for Energy Transfer in Future Electric Vehicles.

Reducing the weight of electric conductors is an important task in the design of future electric air and ground vehicles. Fully electric aircraft, where high electric energies have to be distributed over significant distances, are a prime example. Multifunctional composite materials with both adequate structural and electrical properties are a promising approach to substituting conventional monofunctional components and achieving considerable mass reductions. In this paper, a hybrid multifunctional glass-fiber-reinforced composite containing quasi-endless aluminum fibers with a diameter of 45 µm is proposed for electric energy transfer. In addition to characterizing the material's behavior under static and fatigue loads, combined electrical-mechanical tests are conducted to prove the material's capability of carrying electric current. Light microscopy, thermal imaging and potentiometry-based resistance characterization are used to investigate the damage behavior. It is found that a volume fraction of about 10% work-hardened aluminum fibers does not affect the static fiber-parallel material properties significantly. Under transverse loading, however, the tensile strength is found to decrease by 17% due to the weak bonding of the aluminum fibers. The fiber-parallel fatigue strength of the multifunctional laminate containing work-hardened aluminum fibers is comparable to that of the reference material. In contrast, the integration of soft-annealed aluminum fibers decreases the tensile strength (−10%) and fatigue life (−21%). Concerning the electrical properties, electrical resistance is nearly unchanged until specimen rupture under quasi-static tensile loads, whereas under cyclic loading, it increases up to 60% within the last third of the fatigue life. Furthermore, the material's capability of carrying currents up to 0.32 A/mm2 (current density of 4.5 A/mm2 in the aluminum phase) is proven. Under combined electrical-mechanical loads, a notable reduction in the fatigue life (−20%) is found at low fatigue loads, which is attributed to ohmic specimen heating. To the best knowledge of the authors, this is the first study on the electrical and mechanical material properties and damage behavior of glass-fiber-reinforced composites containing aluminum fibers tested under combined electrical-mechanical loads.

Taurine-Modified Boehmite Nanoparticles for GFRP Wind Turbine Rotor Blade Fatigue Life Enhancement.

Advanced nanoparticle-reinforced glass fibre composites represent a promising approach to improving the service life of fatigue-loaded structures such as wind turbine rotor blades. However, processing particle-reinforced resins using advanced infusion techniques is problematic due to, for example, higher viscosity as well as filtering effects. In this work, the effects of boehmite nanoparticles on viscosity, static properties and fatigue life are investigated experimentally. Whereas rheological analysis reveals a significant increase of viscosity in the case of pristine boehmite particles, an additional taurine surface modification of the particles can effectively reduce viscosity increase. As regards mechanical properties, significant improvements of both static as well as fatigue properties are found. The addition of 15 wt.% of boehmite particles increases fatigue life by a maximum of 270% compared to the unmodified fibre-reinforced epoxy. Transmitted light-based investigation of the damage mechanisms shows delayed initiation and smaller growth rates for laminates containing boehmite particles. At the same time, the observed mechanisms and their accumulation along the relative cycle number do not change significantly. In addition, by characterising autonomous heating, the so-called Risitano fatigue limit is determined. The results reveal that with increasing particle content there is an increase in the fatigue limit.