At the previous SPIE conference in San Diego (2008), the authors presented and compared a range of low-cost optical fibre sensors for monitoring the cross-linking process of a thermosetting resin. The same sensor was used subsequently
to monitor and quantify the diffusion of water in the cross-linked polymer.
The current paper presents recent data on the deployment of an array of low-cost fibre-optic sensors to monitor the water
diffusion front. The data obtained from the sensors are compared with conventional gravimetric measurements and
theoretical predictions for the diffusion profile for water ingress in a cross-linked epoxy/amine resin system.
Whilst considerable progress continues to be made on the design and deployment of fibre optic sensors for chemical
process monitoring and structural integrity assessment, the majority of these sensor designs can only impart information
on one or two relevant measurands. For example, in the case of chemical process monitoring of advanced fibrereinforced
composites involving thermosetting resins, it is generally appreciated that cross-linking kinetics can be
influenced by a number of factors including the following: the stoichiometry of the reagents, temperature, surface
chemistry of the substrate and presence or absence of contaminants. Thermosetting resins also shrink during the crosslinking
process. When thermosets are used and processed above room temperature during the production of fibrereinforced
composites, upon cooling back to ambient temperature, residual stress can develop due to the mismatch in
thermal expansions between the reinforcing fibres and the matrix.
This paper reports on recent progress on the design and demonstration of a novel multi-functional fibre optic sensor that
can provide data on (i) temperature, (ii) strain, (iii) refractive index, (iv) transmission infrared spectroscopy and (v)
evanescent wave spectroscopy. A unique and attractive feature of this sensor is that a conventional commercially
available Fourier transform infrared spectrometer is used to interrogate the sensor. The sensor design is based on an
extrinsic fibre Fabry-Perot interferometer.
The authors have demonstrated previously that reinforcing glass fibres can be used as light-guides to facilitate chemical
process monitoring and structural integrity assessment of fibre reinforced composites. In the current paper, the authors
explore concepts for the development of self-sensing, self-healing and crack-arrestor composites.
The first part of the papers presents a brief overview of previously reported technologies for self-sensing, self-healing
and crack-arrestor; the advantages and disadvantages of the various technologies are discussed. The second part of this
paper present the design concept and performance requirements for the self-sensing, self-healing and crack-arrestor
composites. The final part of the paper presents preliminary results on the manufacture and evaluation of this class of
composite.
Fibre Bragg grating (FBG) sensors continue to be used extensively for monitoring strain and temperature in and on
engineering materials and structures. Previous researchers have also developed analytical models to predict the loadtransfer
characteristics of FBG sensors as a function of applied strain. The general properties of the coating or adhesive
that is used to surface-bond the FBG sensor to the substrate has also been modelled using finite element analysis.
In this current paper, a technique was developed to surface-mount FBG sensors with a known volume and thickness of
adhesive. The substrates used were aluminium dog-bone tensile test specimens. The FBG sensors were tensile tested in
a series of ramp-hold sequences until failure. The reflected FBG spectra were recorded using a commercial instrument.
Finite element analysis was performed to model the response of the surface-mounted FBG sensors. In the first instance,
the effect of the mechanical properties of the adhesive and substrate were modelled. This was followed by modelling the
volume of adhesive used to bond the FBG sensor to the substrate. Finally, the predicted values obtained via finite
element modelling were correlated to the experimental results. In addition to the FBG sensors, the tensile test specimens
were instrumented with surface-mounted electrical resistance strain gauges.
The focus of this paper is on real-time damage detection in reinforcing fiber bundles and composites using high-speed
photography and image analysis. In other words, the end of a reinforcing fiber bundle or composite is imaged and the
sequence of fiber fracture is monitored using a high-speed camera. These studies were undertaken using as-received and
silane-treated custom-made optical fibers of around 12 μm diameter and E-glass fibers of 15 (±3) μm diameter.
The first part of this paper reports on the techniques that were developed to produce void-free test specimens and the
procedures used for imaging the end of the fiber bundle and composite during tensile loading. Evanescent wave
spectroscopy was used to study the effect of silane treatment on the cross-linking kinetics of an epoxy/amine resin
system. Conventional piezo-electric acoustic emission (AE) transducers were used to monitor the acoustic events
occurring during the tensile test. The signals from the AE transducers were used to trigger the high-speed camera.
The second part of this paper presents details of the image analysis routines that were developed to track the light
intensity transmitted through individual fibers during tensile loading. Good correlation was observed between the
transmitted light intensity and the AE signals.
Significant progress has been made in recent years on the design and deployment of optical fibre-based sensors to
monitor the cross-linking (cure) reactions in thermosetting resins. In the current study, the following sensor designs
were used to study cross-linking reactions of an epoxy/amine resin system: (i) intensity-based Fresnel sensors, (ii)
extrinsic fibre Fabry-Perot interferometic (EFPI) sensors, (iii) fibre Bragg grating (FBG) sensors and (iv) sensor designs
to enable transmission, reflection and evanescent wave spectroscopy.
This paper presents a detailed study on a comparison of the above-mentioned techniques for a commercially available
epoxy/amine resin system. Conventional Fourier transform infrared spectroscopy was used as the reference method for
obtaining quantitative data on the cross-linking kinetics. The shrinkage of the resin during cross-linking was monitored
using EFPI and FBG sensors. This paper also discusses the cross-linking data obtained using optical fibre-based
evanescent wave spectroscopy.
This paper presents the design, theory, characterisation and application of a novel fibre optic acoustic emission (AE)
sensor. The sensor consists of a pair of optical fibres that are heated, fused and drawn to create a fused-tapered region
that is sensitive to acoustic perturbations. The sensor is housed in a silica V-groove. The modelling of this fibre optic AE
sensor is presented with a finite element analysis on the strain field based on the effect of the geometry within the
sensing region. The characterisation of the sensor was carried out using a glass block with 160mm thickness as an
acoustic medium. The applications of this sensor were demonstrated in three experiments. Firstly, the sensor was
surface-mounted in carbon fibre reinforced composite samples and tested to failure under tensile loading. In the second
experiment, the sensor was surface-mounted on double-cantilever Mode-I test specimens. The AE response from the
sensor was correlated to the inferred modes of failure during the Mode-I test. In the third experiment, the sensor was
surface-mounted onto the composite "blow-off" test samples. The feasibility of using the sensor to detect damage
development in real-time was demonstrated.
It is generally appreciated that the ingress of moisture in composites can have adverse effects on matrix-dominated
properties such as the glass transition temperature and compressive mechanical properties. Moisture ingress in
composites can also lead to swelling and blistering. A number of excellent studies have been reported on the detection,
modelling and effects of moisture ingress on the properties of thermosetting resins (matrix) and composites. However, it
is generally taken for granted that the quality of the resin and the processing conditions used to cross-link the resin are
identical. Given the recent advances in the design and deployment of optical-fibre sensors in composites, it is now
possible to use the same sensor to facilitate in-situ cure monitoring and structural health monitoring (after processing).
This paper will present recent developments in the design of
low-cost fibre-optic sensor systems for in-situ chemical
process monitoring and the detection of moisture ingress after curing. The cure kinetics derived from three fibre optic
sensor designs is presented as well as those obtained from evanescent-wave spectroscopy using E-glass fibres.
After conducting the in-situ cure monitoring experiments, one of the fibre-optic sensor designs was selected and the
samples (with the embedded sensors) were dried to constant mass at 50°C then transferred to water baths maintained at
70, 50, and 30 °C. The diffusion kinetics for the samples was determined using samples without and with embedded
optical-fibre sensors. The effect of moisture ingress in the resin was also assessed using dynamic mechanical thermal
analysis (DMTA), transmission infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC). Preliminary
results are also presented to demonstrate that the reinforcing fibres in E-glass composites can be used to track the cross-linking
kinetics of a commercial epoxy/amine resin is presented.
The majority of the reported applications on 157 nm ablation of fused silica and sapphire were concerned with surface
micromachining, where the depth of ablation ranges from few hundreds of nanometres to several micrometres. The
control of surface morphology and wall-angle of the microstructures was found to be difficult with increasing ablation
depth. In this paper, the performance of a Kohler-based illumination in conjunction with a low-numerical aperture
imaging system for micromachining cavities through the diameter of standard silica optical fibres and sapphire fibres is
presented. Roughness of wall surface and tapering of cavities at different energy densities have been investigated. Nearparallel
walled cavities micromachined in silica fibres produced Fabry-Perot fringes as a result of interference of light
undergoing Fresnel reflections at the cavity walls. A technique to control the ablation depth of cavities in optical fibres
via in-situ monitoring of laser-induced fluorescence is developed.
Cure monitoring is a term that is used to describe the cross-linking reactions in a thermosetting resin system. Advanced
fiber reinforced composites are being used increasingly in a number of industrial sectors including aerospace, marine,
sport, automotive and civil engineering. There is a general realization that the processing conditions that are used to
manufacture the composites can have a major influence on its hot-wet mechanical properties. This paper is concerned
with the design and demonstration of a number of sensor designs for in-situ cure monitoring of a model thermosetting
resin system. Simple fixtures were constructed to enable a pair of cleaved optical fibers with a defined gap between the
end-faces to be held in position. The resin system was introduced into this gap and the cure kinetics were followed by
transmission infrared spectroscopy. A semi-empirical model was used to describe the cure process using the data
obtained at different cure temperatures. The same sensor system was used to detect the ingress of moisture in the cured
resin system.
Significant progress has been made in recent years on the design and fabrication of optical fibre-based sensor systems
for applications in structural health monitoring. Two sensor designs have tended to dominate namely, fibre Bragg
gratings and extrinsic fibre Fabry-Perot sensors. However, the cost and time associated with these sensors is relatively
high and as a consequence, the current paper describes a simple procedure to fabricate intrinsic fibre Fabry-Perot
interferometric strain sensors. The technique involves the use of hydrofluoric acid to etch a cavity in a cleaved optical
fibre. Two such etched cavities were fusion spliced to create an intrinsic fibre Fabry-Perot cavity. The feasibility of
using this device for strain monitoring was demonstrated. Excellent correlation was obtained between the optical and
surface-mounted electrical resistance strain gauge.
The term self-sensing composites is used to describe the case where the reinforcing glass fibres in advanced fibre reinforced composites are used as the sensors for chemical process monitoring (cure monitoring). This paper presents conclusive evidence to demonstrate that reinforcing E-glass fibres can be used for in-situ cure monitoring. The cure behaviour of an epoxy/amine resin system was compared using evanescent wave spectroscopy via the reinforcing E-glass fibre and conventional Fourier transform infrared spectroscopy. This paper also reports for the first time that evanescent wave spectroscopy via E-glass fibres can be used to detect the presence of silane coupling agents. Preliminary results indicated that the cure kinetics on the E-glass fibre surface, as observed using evanescent wave spectroscopy, were influenced by the silane coupling agent.
This paper reports on two techniques for creating Fabry-Perot cavities in conventional single- and multi-mode optical fibres. The authors have reported previously on the design and fabrication of extrinsic fibre Fabry-Perot interferometric multi-functional sensors. Here, the authors report on two novel techniques for creating intrinsic fibre optic sensors based on the Fabry-Perot etalon. The first technique involved the use of hydrofluoric acid to preferentially etch the core of the optical fibre. This technique is simple to carry out and provides a cost-effective means for manufacturing intrinsic fibre Fabry-Perot sensors. In the second technique, a 157 nm excimer laser along with a custom-designed beam delivery system was used to ablate (micro-machine) near-paralleled walled cavities through the diameter of the optical fibre (outer diameter of 125 μm). The paper details the experimental methodology and the associated instrumentation for the two techniques. The acid etched and laser ablated cavities were characterised using a 3-D surface profiler, optical and scanning electron microscopy. The feasibility of using these cavities as intrinsic fibre Fabry-Perot strain sensors is demonstrated. This was achieved by surface-mounting the acid etched cavities on to composite tensile test specimens. The output from the optical fibre devices was compared with surface-mounted electrical resistance strain gauges.
This paper is concerned with the design concepts, modelling and implementation of various fibre optic sensor protection systems for development in concrete structures. The design concepts of fibre optic sensor protection system and on-site requirements for surface-mounted and embedded optical fibre sensor in concrete structures have been addressed. The aspects of finite element (FE) modelling of selected sensor protection systems in terms of strain-transfer efficiency from the structure to the sensing region also been focused in this paper. Finally, the experimental validations of specified sensor protection system in concrete structures have been performed successfully. Protected Extrinsic Fabry-Perot Interferometric (EFPI) and Fibre Bragg Grating (FBG) sensors have been used to monitor the structural health status of plain and composite wrapped concrete cylinders. Results obtained indicate that the protection system for the sensors performs adequately in concrete environment and there is very good correlation between results obtained by the protected fibre optic sensors and conventional electrical resistance strain gauges.
A number of embedded sensor protection system (ESPS) and surface-mountable sensor protection system (SSPS) for fibre optic sensor (FOS) have been developed in this paper. Fibre Bragg Grating (FBG) and Extrinsic Fabry-Perot interferometric (EFPI) sensors protected by the designed protections system have been used to monitor the cure progress and structural health status of concrete cylinders. Results indicate that the sensor protection systems for the FOS perform adequately and effectively in concrete environment. The protected fibre optic sensors are suitable achieve the structural health monitoring in practical. It is also revealed that there is excellent correlation between the results obtained from the protected FOS and reference electrical resistance strain gauges.
A number of embedded sensor protection system (ESPS) and surface-mountable sensor protection system (SSPS) for fibre optic sensor (FOS) have been developed in this paper. Fibre Bragg Grating (FBG) sensor protected by the designed protections system have been used to monitor the cure progress and structural health status of concrete cylinders. Results indicate that the sensor protection systems for the FOS perform adequately and effectively in concrete environment. The protected fibre optic sensors are suitable achieve the structural health monitoring in practical. It is also revealed that there is excellent correlation between the results obtained from the protected FOS and reference electrical resistance strain gauges.
This paper reports on the synthesis and characterization of a novel class of materials namely, photo-actuating and photo-rheological polymers. The terms photo-actuation and photo-rheological refer to the phenomena, where photo-responsive polymers undergo conformational changes upon UV irradiation. This conformational change can result in changes in the spectral and physical properties of the polymer. For example, its volume and rheological properties. The first part of this paper describes the laboratory-based synthesis and characterization of these materials. The second part describes the experimental methodology and results obtained when characterizing the photo-actuation and photo-rheological behavior of the materials. It was paramount in these experiments to control the temperature of the test specimen; this was necessary as some of the changes in the properties brought about by UV irradiation could also be accounted for by an increase in the temperature of the test specimen.
Two classes of photo-responsive material were synthesized and characterized using conventional analytical techniques. The first series of polymers were polymethyl methacrylate (PMMA) based with azobenzene groups in the side chain, the second series contained spiropyran groups in the side chain. The characterization of the photo-rheological behavior of these materials involved the deployment of a custom-modified rheometer, which was operated under isothermal conditions. A liquid light guide was used to enable in-situ irradiation of the test specimen with UV or visible light. The photo-actuation studies involved experiments on liquids and solid films of the above-mentioned co-polymers. A commercially available 3-D surface profiler was used to study their photo-actuating behavior. A couple of unique apparatus were also designed and used to characterize the photo-actuation behavior of the polymers in solution.
The effects of irradiation on the photo-rheological and photo-actuating behavior were quantified taking temperature effects into consideration. Potential end-use applications for these polymers are considered.
This article describes a novel technique to obtain simultaneous spectral, thermal and dilatometric data on polymers as they are heated through their glass transition temperatures and melting points. The technique links an infrared spectrometer and an optical spectrum analyser, through a combination of fibre optic probes, to a custom-modified differential scanning calorimeter. The latter is used to obtain thermal-based information such as the enthalpy of fusion and the glass transition whilst the infrared spectrometer is used to obtain chemical information of the polymer sample. The optical spectrum analyser was used in tandem with the fibre optic probe to obtain simultaneous dilatometric data off the processed sample using an interferometric technique. This combined and simultaneous analytical technique negates the need for three independent experiments to obtain thermal, spectral and chemical information. Another advantage of this simultaneous technique is that the polymer sample is subject to a single and controlled thermal environment.
This paper introduces a new type of fiber-optic acoustic emission (AE) sensor, based on a fused tapered 2x2 coupler. Laser light is injected into one input fiber and variations in the splitting ratio, caused by the passage of an ultrasonic pulse through the coupling region, are measured via a differential detection scheme. The sensor was designed to be directly compatible with an existing AE instrumentation system (the MISTRAS system from Physical Acoustics). Sensors were mounted on the surface of and embedded within glass-reinforced polyester laminates. They were excited with simulated AE signals and their performance was compared to that of a conventional piezoelectric AE transducer. The characteristics of the response of the fiber-optic sensor were similar to those of a commercial piezoelectric transducer. A signal-to noise ratio of 45 dB was achieved.
Optical fiber-based extrinsic Fabry-Perot interferometric (EFPI) sensors have been extensively deployed for sensing a number of measurands including temperature, strain, vibration and pressure. Their circular cross-section has made it relatively simple and attractive to embed them in advanced fibre reinforced composites (AFRCs) such as glass and carbon fibers. However, a typical construction of an EFPI consists of two optical fibers that are positioned and secured within a precision bore capillary. The relative outer diameters of the various key components are as follows: capillary = 300 micrometers ; optical fibre = 125 micrometers ; carbon and glass fibers = 8 and 14 micrometers respectively. This mismatch in relative diameters of the reinforcing and the sensor fibers can result in significant spatial distortion of the former. The location of the embedded sensing fibre in relation to the reinforcing fibre layers can also lead to the formation of resin-rich regions in the AFRC. These factors can have a detrimental effect on the compressive properties of the material. Therefore, there is significant attraction in reducing the overall diameter of the sensor. In this current paper, the feasibility of reducing the diameter of EFPI sensor design to that of the optical fibre is demonstrated via two techniques. The first technique involved the use of hydrofluoric acid to etch and create the Fabry-Perot cavity. In the second technique, the feasibility of using laser ablation to fabricate the Fabry-Perot cavity in silica and sapphire substrates is presented. The optical fibre-based Fabry-Perot cavity produced via acid etching was interrogated using white light interferometry.
A fiber acousto-optic device is analyzed experimentally, which based on a single mode fiber coupler. The cutoff wavelength and splitting ratio in 630 nm are about 600 nm and 3 dB. When a strain wave acts on the packaged fiber coupler, the splitting ratio of the coupler will be changed which cause the modulation of output in the fiber coupler. At some frequency of strain wave, the modulation will get at Maximum.
We present three types of intensity-based fiber-optic accelerometer with two axes of sensitivity. Transmission and reflection, or single-ended sensor configurations are compared and bare fibers or a machined brass element are used a seismic masses. The devices are shown to be capable of measuring accelerations at relatively low frequencies (below 1 kHz). Linear responses to acceleration were observed up to the limit of the testing apparatus and the crosstalk between vibration directions was always -12 dB or less.
The analysis of acoustic emission signals has been widely applied to damage detection and damage characterization in composites. Features of acoustic emission signals, such as amplitude, frequency, and counts, are usually utilized to identify the type of a damage. Recently, time-frequency distribution techniques, such as the wavelet transform and the Choi-Williams distribution, have also been applied to characterize damage. A common feature of these approaches is that the analysis is on the acoustic emission signal itself. Nevertheless, this signal is not the wave source signal as it has been modulated by the signal transfer path. Real information on damage is actually hidden behind the signal. To reveal direct information on damage, a blind deconvolution method has been developed. It is a quefrency domain method based on the cepstrum technique. With the method, acoustic emission signal is demodulated and information on the wave source can be revealed and thus damage can be identified. This paper presents preliminary test data to assess the validity of the proposed methodology as a means of identifying specific damage modes in fiber reinforced composites.
The aerospace industry has seen a considerably growth in composite usage over the past ten years, especially with the development of cost effective manufacturing techniques such as Resin Transfer Molding and Resin Infusion under Flexible Tooling. The relatively high cost of raw material and conservative processing schedules has limited their growth further in non-aerospace technologies. In-situ process monitoring has been explored for some time as a means to improving the cost efficiency of manufacturing with dielectric spectroscopy and optical fiber sensors being the two primary techniques developed to date. A new emerging technique is discussed here making use of piezoelectric wafers with the ability to sense not only aspects of resin flow but also to detect the change in properties of the resin as it cures. Experimental investigations to date have shown a correlation between mechanical impedance measurements and the mechanical properties of cured epoxy systems with potential for full process monitoring.
The processing of advanced fiber reinforced composites requires accurate data on the temperature and chemical composition of the resin system as a function of time. This paper reports on a preliminary study to evaluate two multi- functional sensor arrangements to facilitate in-situ chemical and temperature monitoring in epoxy resin-based thermosets. Sensor arrangements evaluated for chemical analysis include evanescent wave and transmission-based near-infrared spectroscopy; and for temperature monitoring optical fiber Bragg gratings. A comparative analysis was undertaken to ascertain the relative merits of each sensor configuration.
With the increasing recognition that optical fiber-based sensor systems are ideal for structural health monitoring, there is a demand for a low-cost sensor. This paper reports on recent progress in the design, manufacture and evaluation of an intensity-based optical fiber strain sensor. The proposed sensor is referred to as the 'profile' sensor and it is made by deforming (tapering) a section of optical fiber using a standard fiber fusion splicer. Up to three profiles were made on a single fiber length and the attenuation during this process was monitored. The sensors were photographed to estimate the dimensions of the profile and then tensile tested by attaching the profile sensor to a micrometer stage. The sensors were strained via the micrometer stage in an incremental manner and the light transmission was monitored during this operation. An increase in the light transmission characteristics was observed during tensile loading. A good correlation was obtained between the experimental results and the predicted values.
Amine/epoxy based thermosets are used as matrices in a wide variety of advanced fiber reinforced composite structures. Thermosets can be formulated for specified processing routes, for example, pultrusion, prepregging, resin transfer moulding and filament winding. In general, the resin system has two or more components, which have to be mixed prior to use. Issues of concern in this area are (1) the homogeneity of the mixed resin systems; (2) the stoichiometry of the reagents and (3) the chemical stability of the individual components as a function of storage conditions prior to mixing. The availability of an on-line 'resin quality' sensor system could overcome some of the above mentioned problems. This paper reports on an on-line monitoring system for determining the amine concentration in an amine/epoxy-based thermoset, which is used for filament winding. The system is based on a dual- wavelength optical fiber sensor design. One light source at 1548 nm corresponds to the amine (N-H) absorption band and the second is centered around 670 nm. The latter serves as a reference to compensate for the scattering effects. The proposed system is capable of quantitatively determining amine concentrations during processing and offers the option of on- line process optimization for multi-component resins.
The authors demonstrate that several optical fiber Fabry-Perot sensors can be multiplexed in series for axial strain monitoring at each individual sensor. White light interferometry was employed using the laser-referenced Michelson interferometer of a standard Fourier transform spectrometer as a receiving (interrogating) interferometer. The primary aim was to demonstrate that at least six fiber Fabry-Perot transducer interferometers (sensors) can be multiplexed in series provided that each sensor has a unique optical cavity length within the multiplex. The resulting differing optical path differences at each fiber Fabry-Perot sensor give rise to sharp correlation features (side-bursts) at unique positions in the time domain as observed in the interferogram. An optical cavity length change due to an axial strain perturbation is observed as a change in the position in the time-domain of the side-burst feature associated with the fiber Fabry-Perot sensor. This paper demonstrates that multiplexed strain metrology in the quasi-static regime using fiber Fabry-Perot sensors is possible with a measurement range of typically 0 to 4000 microstrain and a strain resolution of better than 10 microstrain.
This paper reports on a novel optical fiber sensor configuration for conducting simultaneous strain and temperature measurements. The sensor consisted of an optical fiber-based extrinsic Fabry-Perot interferometer (EFPI) with an integrated fiber Bragg grating (FBG). The FBG was located within a glass capillary which housed the EFPI sensor and was thus in a strain-free condition. The FBG is primarily sensitive to temperature, while the EFPI was sensitive to both strain and temperature. The integrated FBG/EFPI sensor was embedded in a carbon fiber reinforced composite and evaluated. The standard deviation of strain measurement was 36 (mu) e in the range 0 to 1200 (mu) e, and the temperature measurement had a standard deviation of 3.5 degrees C in the range 30 degrees to 70 degrees C. The thermal expansion of the cross-ply composite was investigated and was found approximately 4.05 X 10-6 degrees C.
This paper reports on a novel optical fiber-based sensing scheme for conducting simultaneous strain and temperature measurements. The sensor design involved the use of an extrinsic Fabry-Perot interferometric strain sensor and a rare-earth doped fiber fluorescence decay-time based temperature sensor. The combined sensors were embedded in a carbon fiber reinforced composite system and evaluated. The feasibility of using this embedded sensor configuration for simultaneous strain and temperature measurements was demonstrated.
Advance fiber reinforced composites are used extensively for primary and secondary load-bearing applications. In general, the resin systems used in the manufacture of fiber reinforced composites are multi-component. In other words, they generally contain a resin, hardener and a catalyst. The thermal, mechanical and chemical properties of these materials are strongly influenced by the extent of mixing and the cure schedule which is used to cure the resin. This paper presents preliminary results in the deployment of a static resin mixer system to ensure efficient mixing of the resin system. This paper also reports on initial result on the feasibility of using a simple optical fiber-based sensor system to (a) infer the extent of mixing in the multi- component resin, (b) monitor the chemical integrity of the resin. Differential scanning calorimetry was also use to assess the influence of mixing efficiency on the enthalpy of the cure reaction. The technology reported here has significant implication to composite manufacturing processes which involve the use of resin bath. The contribution of the proposed technology to Clean Technology is also discussed.
This paper reports on developments in the field of self- sensing fiber reinforced composites. The reinforcing fibers have been surface treated to enable them to act as light guides for short distances. The reinforcing fiber light guides were embedded in carbon fiber reinforced epoxy prepregs and processed into composites. The resultant composite was termed the self-sensing composite as any damage to these fibers or its interface would result in the attenuation of the transmitted light. The self-sensing fibers were capable of detecting a 2 J impact.
The detection of impact damage in fiber reinforced composites is of significant concern because such damage can reduce the load-bearing ability of the composite. A number of factors can influence the nature and extent of impact damage development in composites including: (1) the type of reinforcing fiber and resin system; (2) the magnitude of the residual (fabrication) stresses; (3) the lay-up sequence; and (4) other factors such as the nature of the impactor, impact velocity, impact energy, temperature, moisture content in the composites etc.. From a structural health monitoring point of view, it is necessary to investigate the distribution of damage through the thickness of the composite. This paper reports on a simple, partially multiplexed optical fiber strain sensor system for in-situ strain and residual strain measurements in a carbon fiber reinforced epoxy composite. An extrinsic Fabry-Perot interferometric (EFPI) sensor design was used along with single mode fibers. The multiplexing scheme was based on wavelength division via the use of two super luminescent diodes at different wavelengths. A low-cost fiber optic CCD spectrometer was used as the detector. The multiplexing scheme was demonstrated using two EFPI sensors. In principle, a number of EFPI sensors can be multiplexed using the proposed scheme provided that each sensor is illuminated at a specified and different wavelength. The feasibility of detecting the residual strain in the composite was demonstrated successfully at two specified positions within a 16-ply carbon fiber reinforced composite. Preliminary results indicated that the sensor system was also capable of detecting the effects of a 3.2 J impact. Excellent correlation was obtained between the EFPI sensor output and that obtained using surface mounted strain gauges.
Optical fiber Bragg grating (FBG) sensors have significant potential for use as embedded devices to monitor the structural integrity of engineering materials. The main drawback of the FBG strain sensor is its cross-sensitivity to temperature. This paper reports a simple scheme for multiplexing a FBG and an extrinsic Fabry-Perot interferometric (EFPI) sensor to enable the decoupling of strain from temperature. The EFPI sensor was constructed using a precision bore quartz capillary tube which housed two cleaved optical fibers. The gap between the fiber end- faces served as the Fabry-Perot cavity. Since the coefficients of thermal expansion between the optical fiber and the capillary tube were similar, the EFPI sensor has a very low sensitivity towards temperature. Therefore, when both sensors are placed close together, the EFPI sensor can act as the strain sensor, and temperature can be determined from the FBG wavelength shift after taking out the strain effect. The signal processing for the EFPI sensor was based on a channelled spectrum method using a CCD spectrometer. The same CCD spectrometer was also used to determine the wavelength shift of the FBG. The cross-talk between the EFPI and FBG sensors was evaluated. The feasibility of conducting simultaneous strain and temperature measurements was demonstrated.
This paper reports on a comparative study undertaken for different types of optical fiber sensor developed to monitor the cure of an epoxy resin system. The optical fiber sensors used to monitor the cure process were based on transmission spectroscopy, evanescent wave spectroscopy and refractive index monitoring. The transmission sensor was prepared by aligning two optical fibers within a specially prepared sleeve with a gap between the optical fiber end-faces. During cure, resin from the specimen flowed into the gap between the optical fibers allowing transmission spectra of the resin to be obtained. The evanescent wave sensor was prepared by stripping the cladding from a high refractive index core optical fiber. The prepared sensor was embedded in the sample and attenuated total reflectance spectra recorded from the resin/core boundary. Refractive index monitoring was undertaken using a high refractive index core optical fiber which had a small portion of its cladding removed. The prepared sensor was embedded in the resin specimen and light from a single wavelength source was launched into the fiber. Changes in the guiding characteristics of the sensor due to refractive index changes at the resin/core boundary were used to monitor the progress of the cure reaction. The transmission and evanescent wave spectroscopy sensors were used to follow changes in characteristic near-infrared absorption bands of the resin over the range 1450 - 1700 nm during the cure reaction. Consequently these techniques required tunable wavelength sources covering specific wavelength ranges. However, the refractive index based sensor used a single wavelength source. Therefore the equipment costs for this type of sensor were considerably less. Additionally, the refractive index sensor did not require a single wavelength source at any particular wavelength and could be applied to any spectral region in which the optical fiber would transmit light. The advantages and disadvantages of these three methods are discussed.
This paper presents preliminary work on a vibration monitoring system for assessing the condition of engineering structures or materials. It consists of an intensity-based fiber-optic vibration sensor, a fast Fourier transform pre- processing stage and a back-propagation neural network. The response of the vibration sensor to sinusoidal acceleration is compared with that of a piezoelectric accelerometer. The sensor was fixed to carbon-fiber composite panels and its response to acoustic transients was investigated. Signals from breaking a pencil lead or dropping a ball bearing on the panel were compared. The system was then trained to distinguish between the sensor response to dropping a ball bearing on panels with either real or simulated impact damage. The trained network then identified previously unseen examples of these signals with complete accuracy.
Conventional E-glass fibers were surface treated to enable them to act as light guides for short distances. The reinforcing fiber light guides were embedded in glass fiber reinforced epoxy prepregs and processed into composites. The resultant composite was termed the self-sensing composite as any damage to these fibers or its interface would result in the attenuation of the transmitted light. Epoxy, silicone, fluoropolymer and sol-gel derived cladding materials were evaluated as potential cladding materials. RFLGs with a silicone coating was found to give the best light transmission. The self-sensing fibers were capable of detecting a 0.5 J direct impact. The feasibility of using the RFLGs for impact damage location was also demonstrated successfully as bleeding-light could be seen in the vicinity of the impact.
This paper reports on the use of a multimode extrinsic fiber Fabry-Perot interferometric sensor for quasi-static and dynamic fatigue loading experiments. A surface mounted extensometer was also used to measure the strain in the composite as a function of applied load. Excellent correlation was obtained between the strain data from the extensometer and the embedded EFPI sensor. With reference to dynamic loading, the sensor was found function reliable up to 1,600,000 cycles when the fatigue test was terminated. The fatigue tests were carried out using a peak stress of 260 MPa with a stress ratio of negative 0.40, and a frequency of 5 Hz. The signal processing technique was based on a channelled spectrum CCD spectrometer. The sensitivity of quasi-static strain measurements was approximately 30 micro-strain with a strain range of approximately negative 1% to 1%. The feasibility of using the EFPI sensor for stiffness-decay measurements during fatigue testing of composites was demonstrated. Preliminary results form the use of a single-mode EFPI sensor design for strain measurements in composites is also presented.
This paper reports on the feasibility of monitoring the cure of an epoxy-amine resin system using a transmission-based optical fiber sensor and near-infrared spectroscopy. The sensor was prepared from two silica fibers aligned within a notched precision bore capillary tube to produce a robust transmission cell without the need for complicated alignment. The resin system used consisted of Shell Epikote 828 (resin) and 1,6-hexanediamine (hardener). Using the optical fiber sensor, spectra were collected throughout the cure over the wavelength range 1450 - 1700 nm. Cure data from the optical fiber sensor were compared with Fourier transform infrared spectroscopy (FTIR) experiments carried out at similar cure temperatures. The cure kinetic data were generated as a function of temperature for stoichiometric mixtures of the resin and hardener. An attempt was made to fit the cure data from the above mentioned techniques to a semi-empirical model. Good correlation was obtained between the cure model and the optical fiber cure data.
An optical fibre Bragg grating (FBG) sensor was surface mounted onto a carbon fibre reinforced epoxy
composite and subjected to static and dynamic loading. The FBG sensor was found to operate satisfactorily up
to 700,000 cycles when the fatigue test was terminated. The fatigue test was conducted at a peak stress of 210
MPa and a stress ratio of -0.5. The FBG sensor was also found to operate satisfactorily over the cyclic loading
frequency range of 0.1 - 6 Hz used in this study. The feasibility of using the sensor system for monitoring the
stiffness ofthe composite during the fatigue test was demonstrated. The signal processing for the sensor system
was based on a CCD spectrometer. The sensitivity of the static strain measurements was found to be
approximately 80 jtc. A broadening ofthe FBG reflective spectrum was seen to develop as a function of fatigue
cycles, and this phenomenon may be due to the delamination ofthe sensor from the surface ofthe composite.
This paper presents a general overview of intensity-based optical fiber sensor systems, including those developed at Brunel University for condition and health monitoring of engineering materials. The sensor systems covered are: crack detection, a novel technique for converting glass reinforcing fibers into light guides for sensing applications, vibration monitoring and a new intensity- independent demodulation technique for fiber Fabry-Perot interferometers.
This paper discusses the development of a novel composite system where some of the reinforcing fibers act as the light guide. High purity silica reinforcing fibers with a diameter of 9 micrometer were used along with an appropriate cladding material to produce a light guide, which was termed a 'self-sensing' fiber. Self-sensing fibers were embedded within a 16-ply carbon fiber reinforced composite and the resultant panels were impact tested to examine the possibility of using the self-sensing fibers as an impact damage sensor (crack detector). Similarly, three types of conventional optical fibers, with outer diameters of 30 micrometer, 50 micrometer, and 125 micrometer were also embedded within composite panels. These were also impact tested to ascertain their effectiveness as crack detectors. Results indicate that the self-sensing fibers are capable of detecting impact damage as low as 2 J and proved to be more sensitive to impact damage than the other types of fiber investigated in this study.
Two types of optical fiber sensors (OFS) were investigated for use in monitoring the cure of an epoxy-amine resin system: (1) an evanescent wave sensor and (2) a refractive index sensor. The evanescent wave sensor was used to detect changes in concentration of the active chemical species involved in the cure reaction via evanescent wave near-infrared spectroscopy. By using the optical fiber as an attenuated total reflection waveguide, spectra were collected over the range 1490 - 1570 nm at regular time intervals during the cure. This technique enabled the depletion of amine to be monitored. Results obtained via this method were fitted to kinetic models which allowed prediction of the reaction rate at different cure temperatures and conversions. The optical fiber evanescent wave sensor results were compared with data obtained using an established cure monitoring technique (FT-IR spectroscopy). A theoretical model of the evanescent sensor has been used which describes the relationship between evanescent absorption as a function of absorber concentration and refractive index. Predictions of sensor response were undertaken using absorption data from FT-IR spectroscopy and refractive index results as a function of cure time. The predicted sensor response was then compared with experimentally obtained sensor data. An optical fiber sensor which monitored the cure process via refractive index change was also investigated. Sensors were set up to allow simultaneous collection of data during cure from the OFS, together with data from transmission near-infrared spectroscopy and Abbe refractometry. In this way the response of the sensor to changes in the cure state of the resin, refractive index and temperature was compared.
A compact intensity-based fiber-optic vibration sensor, suitable for embedment or surface- mounting has been designed and evaluated. It employs simple and inexpensive instrumentation, and is shown to be responsive to frequencies in the range of 100 - 10,000 Hz. It was mounted onto the surface of specimens of carbon fiber reinforced composite, and proved to be capable of differentiating between the vibrational responses of damaged and undamaged panels. An attempt was made to characterize the sensor's output signal by FFT processing. The sensor also survived embedment in a cementitious composite panel. It is proposed that the device can be used as the sensing element of a real-time mechanical-health- monitoring system.
An embedded, intensity-based fiber optic sensor was previously designed and evaluated for strain monitoring in advanced fiber reinforced composites under dynamic loading conditions. The original sensor design involved the use of two multimode fibers, each with a cleaved end. These fibers were fitted into a glass capillary and were secured in position via a fusion splice at each end of the capillary. However, the effective operational strain range of this sensor design was limited primarily to tensile loading. In order to use this sensor under compressive loading regimes, it was necessary to develop a technique to construct the sensor with a known separation of the fiber end-faces. In effect, the sensor is an extrinsic Fabry-Perot interferometric sensor. The signal processing was based on a scanning monochromator. The feasibility of using the optical fiber sensor for tensile and compressive strain measurements was demonstrated. The sensor was also used to obtain in-situ stiffness reduction data during the fatigue testing of a cross-ply carbon fiber reinforced composite. An analysis of the relationship between detection sensitivity and sensor geometry is also presented.
This paper describes a comparative study of in-situ cure monitoring and cure modelling by three methods: (a) evanescent wave spectroscopy, (b) refractive index change, (c) near- infrared spectroscopy. Optical fibers were embedded into aerospace epoxy resins during the manufacturing process of the composite. The cure characteristics were then tracked in real- time during the processing of the material via evanescent wave interaction. This technique is based upon monitoring of characteristic infrared absorption bands of the resin system to find the concentration of the epoxy and amine hardener as a function of cure time. Hence this technique is suitable for on-line process monitoring and optimization. Results obtained from the optical fiber sensors were used to model the curing behavior of the resin system. The results were compared with near-infrared spectroscopy and differential scanning calorimetry experiments carried out under similar conditions. The feasibility of utilizing refractive index changes to monitor the extent of cure has also been demonstrated.
The detection of fatigue damage within composite materials is vital for the safe use of these materials in engineering structures. Embedded fiber-optic sensors have been identified as suitable for damage detection in these materials, as they have minimal interference with bulk composite properties. The relationship between fatigue damage within a composite material and the associated moduli changes have been used to characterize damage development and progression. An intensity based fiber-optic strain sensor has been designed and evaluated for damage detection in composite laminates. This intensity sensor has the ability to monitor rapid strain changes without loss of the reference level. This sensor utilizes relatively simple and inexpensive instrumentation. In this study the fiber-optic strain sensor has been embedded within a 16 layer cross-ply carbon/epoxy laminate. The response of the sensor has been compared to that obtained from strain gauges and an extensometer. The composite coupons with the embedded sensors have also been subjected to tension-tension and tension- compression fatigue. The stiffness decay of the composite during fatigue loading was monitored in real-time.
Filament wound tubes are currently being used extensively in service because of their superior specific properties and the relatively simple manufacturing technique involved in their properties. However, the reinforcing fibers can suffer from low velocity impact damage (approximately 10 ms-1) during service. Such damage can result in poor post- impact properties which in certain applications can reduce the burst strength below safe working levels. This paper discusses the use of optical fiber sensors, embedded during the filament winding process, to provide information on specified levels of impact damage incurred by the tube during service. The sensors being developed use silica based optical fibers in composites made from E-glass reinforcing fibers and high temperature cure epoxy resins. Various methods of damage detection are being evaluated to select the optimum sensor arrangement. These systems detect changes in the transmission characteristics of the optical fiber. The objective being to produce a working damage detection system which provides sensitive, cheap, accurate and reliable information about the levels of impact damage sustained by the tube. This paper presents initial results from the impact damage detection systems being evaluated for use in filament wound tubes. Issues relating to chemical compatibility between optical fiber sensors and the epoxy resin system were also investigated as part of this study. These results aid selection of the correct optical fiber properties to achieve reliable and sensitive systems. The advantages of using a new profile sensor compared to an optical fiber are also discussed.
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