Metallic coating techniques for fiber Bragg grating sensors

Embedded fiber Bragg grating (FBG) sensors are attractive for in-situ structural monitoring, especially in fiber reinforced composites. Their implementation in metallic structures is hindered by the thermal limit of the protective coating, typically a polymer material. The purpose of this study is to demonstrate the embedding of FBG sensors into metals with the ultimate objective of using FBG sensors for structural health monitoring of metallic structures. To that end, ultrasonic additive manufacturing (UAM) is utilized. UAM is a solid-state manufacturing process based on ultrasonic metal welding that allows for layered addition of metallic foils without melting. Embedding FBGs through UAM is shown to result in total cross-sectional encapsulation of the sensors within the metal matrix, which encourages uniform strain transfer. Since the UAM process takes place at essentially room temperature, the industry standard acrylate protective coating can be used rather than requiring a new coating applied to the FBGs prior to embedment. Measurements presented in this paper show that UAM-embedded FBG sensors accurately track strain at temperatures higher than 400 °C. The data reveals the conditions under which detrimental wavelength hopping takes place due to non-uniformity of the load transferred to the FBG. Further, optical cross-sectioning of the test specimens shows inhibition of the thermal degradation of the protective coating. It is hypothesized that the lack of an atmosphere around the fully-encapsulated FBGs makes it possible to operate the sensors at temperatures well above what has been possible until now. Embedded FBGs were shown to retain their coatings when subjected to a thermal loading that would result in over 50 percent degradation (by volume and mass) in atmospherically exposed fiber.

Fiber optic sensors (FOS) in long-term structural health monitoring (SHM) have drawn significant attention due to their pivotal role in detecting defects and measuring structural performance in diverse infrastructures. While using FOS, temperature variation due to environmental factors is still considered one of the major challenges to isolating sensing parameters. To address this issue, we reported a machine learning (ML)-augmented multi-parameter sensing system that enables simultaneous detection of strain and temperature effects based on one single fiber Bragg gratings (FBGs) sensor for SHM. The initial phase entailed designing, fabricating, and characterizing a novel FBG sensor in the laboratory, incorporating a set of four FBGs, each distinguished by distinct Bragg wavelengths. In the next phase, ML algorithms are employed to separate temperature effects from strain variations. As a proof of concept, mechanical loading tests are conducted on the sensor, exposing the FBG portion to various temperature conditions. In the final phase, data collected from a post-tensioned concrete bridge embedded with both strain and temperature FBG sensors are utilized, and the developed ML models are applied to observe real-environment outcomes. Despite the limited feature points of collected FBG spectrums, the developed ML models effectively address cross-sensitivity issues induced by temperature perturbations. The long-term benefit of using FOS is that it will enable a better understanding and utilization of aging infrastructure. This will potentially reduce embodied carbon of infrastructure in the future and assist in the global efforts to achieve Net-Zero.

Railway tracks are the direct supporting structures of the trains, which are vulnerable to produce large deformation under the temperature stress or subgrade settlement. The health status of track is critical, and the track should be routinely monitored to improve safety, lower the risk of excess deformation and provide reliable maintenance strategy. In this paper, the distributed optical fiber sensor was proposed to monitor the continuous deformation of the track. In order to validate the feasibility of the monitoring method, two deformation monitoring tests on one steel rail model in laboratory and on one real railway tack in outdoor were conducted respectively. In the model test, the working conditions of simply supported beam and continuous beam in the rail model under several concentrated loads were set to simulate different stress conditions of the real rail, respectively. In order to evaluate the monitoring accuracy, one distributed optical fiber sensor and one fiber Bragg grating (FBG) sensor were installed on the lower surface of the rail model, the strain measured by FBG sensor and the strain calculated from FEA were taken as measurement references. The model test results show that the strain measured by distributed optical fiber sensor has a good agreement with those measured by FBG sensor and FEA. In the outdoor test, the real track suffered from displacement and temperature loads. The distributed optical fiber sensor installed on the rail can monitor the corresponding strain and temperature with a good accuracy.

We report on the use of a frequency-rnodulated continuous wave (FMCW) technique for multiplexing fiber Bragg grating (FBG) sensors. This technique is based on the modulation of light intensity from a broadband source by a linear swept-frequency RF carrier. Signals from the FBG sensors located at different positions in an array are separated in frequency-domainand demodulated using a tunable optical filter. The potential and limitation of the technique are discussed. A 3-sensor FMCWmultiplexed FBG array of parallel topology and a 6-sensor hybrid FMCWIWDM system were experimentally demonstratedwith -30 dB crosstalk between sensors and 2 tc resolution in terms ofroot-mean-square strain value.Keywords: optical fiber sensors, fiber Bragg grating sensors, frequency-modulated continuous wave, strain measurements. 1. Introduction Fiber Bragg gratings (FBGs) have been identified as an enabling technology for a variety of applications from aerospace, marine, to civil engineering structural monitoring, from medical, nuclear power industry, to electrical power industry[1]. In many applications such as condition monitoring of civil structures such as highways, bridges and buildings. FBG sensorsneed to be multiplexed in order to achieve quasi-distributed measurement and to reduce cost per sensing point to compete withconventional electrical or optical sensors.The most popular technique for multiplexing FBG sensors is the wavelength division multiplexing (WDM) technique[2,3]. The maximum sensor number that can be multiplexed using the WDM technique is determined by the ratio ofthe sourcespectral width over the spacing between the Bragg wavelengths of the FBGs. For applications requiring a larger multiplexinggain, a combination ofthe WDM and time-division multiplexing (TDM) techniques [3] may be used.A TDM system employs a pulsed or gated CW source to illuminate gratings in sequence as the pulse travels along thefiber, the reflected signals from the gratings are separated in time domain [4]. The physical separation between the gratings isdetermined by the input pulse width. A fast time-gated photodetector can be used to select the signal from an individual grating

Recently, it has become necessary to develop a monitoring technology that combines an FBG (fiber Bragg grating) sensor as a means for continuously monitoring whether the reinforcing effect of an FRP (fiber-reinforced polymer) is maintained on FRP-reinforced structural members. However, most existing research focuses on the insertion of FBG sensors into bar-shaped FRPs, and there is a lack of studies that analyze the details for an FRP strip combined with FBG sensors. In this regard, this paper seeks to develop a reinforcement for an NSM (near-surface-mounted) retrofit in which an optical fiber with an FBG sensor is combined with FRP strips. For this, a series of experiments were performed to find the adhesive strength of optical fiber-epoxy-FRP interfaces, the tensile strength of the FBG sensor part of optical fiber with a reflection lattice, and the sensing performance depending on the adhesion length between the optical fiber and the FRP strips. As a result of the study, the adhesion length not less than 20 mm in one direction from the center, with a total adhesion length of 40 mm, needs to be secured when the optical fiber with an FBG is attached and fixed between the two FRP strips with epoxy. In addition, it is expected that the proposed model can be used to properly predict the strain transfer of an FRP strip with a fiber optic sensor and can also be utilized when determining optimum dimensions.

Compared with metal materials, Carbon Fiber Reinforced Plastic (CFRP) is more excellent in performance, with high specific strength and high specific modulus. And among various CFRP structural elements, CFRP laminated plates have widespread applications. However, some indiscernible and hidden primary damage always appears on the CFRP laminated plate and will continuously evolve and expand after being loaded. This work starts with the analysis of the relationship between the changes of the strain distribution and damage expansion of CFRP laminated plates and proposes the damage recognition method of CFRP laminated plates based on strain information. Then, the CFRP laminate damage monitoring system based on Fiber Bragg Grating (FBG) sensor is established, and the CFRP laminate damage identification experiment based on FBG sensor is made to verify the accuracy of the CFRP laminate damage identification method. The results show that the maximum error between the load when the damage appears on the FBG sensor and that when the damage of CFRP laminated plates expands based on the simulated analysis does not exceed 16%. The accuracy of the damage recognition method of CFRP laminated plates is verified and the damage recognition of CFRP laminated plates and their expansion process is achieved.

Structural Health Monitoring (SHM) of aircraft structures, especially composite structures, has assumed increased significance on considerations of safety and costs. With the advent of co-cured structures, wherein bonded joints are replacing bolted joints there is a concern regarding skin-stiffener separation, which might not be detected unless a rigorous non-destructive testing (NDT) is done. It would hence be necessary to be able to detect and assess skin-stiffener separation in composite structures before it reaches the critical size. One of the health monitoring strategies is through strain monitoring using fibre optic strain sensors such as Fibre Bragg Grating (FBG) sensors. The first aspect that needs to be addressed is the characterization of the FBG sensors. Issues of embedment in composites have also to be addressed. Before evolving a damage detection strategy, the sensitivity of the structural strain to skin-stiffener separations must be clearly understood and quantified. This paper presents the analysis and experiments done with a composite test box to study the effect of skin-stiffener separation on the strain behaviour. The box consists of two skins stiffened with spars made of Bi-Directional (BD) glass-epoxy prepreg material. The spars are bolted to the skins and removing suitable number of bolts simulates 'de-bonds'. The strains of the healthy box are compared with the unhealthy box. The strains in the experiments are monitored using both strain gauges and Fibre Bragg Grating (FBG) sensors. The experimental results show that there is significant change in the measured strain near and away from the debond location. The finite element analysis of the box is done using ABAQUS and the analysis is validated with the experimental results. A neural network based methodology is developed here to detect skin-stiffener debonds in structures. A multi-layer perceptron (MLP) neural network with a feed forward back propagation algorithm is used to determine the size/severity of damage. The FE model is used to generate the neural network training data for various sizes of debonds. The results show that the network is able to predict the damage size well. The network is implemented for a specified load. However, it is seen that the damage size predicted is independent of the applied load and the network performance is dependent on the fidelity of the finite element model used to train the network.

Composite structures with embedded fiber optic sensors: A smart propellant tank for future spacecraft applications

In this paper, one large Fiber Bragg Grating (FBG) sensor sensing network for bridge local health monitoring was studied, designed and implemented to Harbin Sifangtai Bridge, China. According to the hot point principle and finite element analysis results, FBG sensors installation scheme was made to monitor the local strain of key elements, respectively. 60 FBG sensors had been installed in monitoring points along the height of I-shape girders distributed in three main monitoring sections along the bridge. Monitoring results in load testing period was obtained, the static and dynamic results show that FBG sensors can monitoring the local strain precisely, and the local strain response is in the safe range under test vehicle load. Monitoring results in service period was obtained, 9 months after load test. Results show that maximum local strain responses in three main monitoring sections are in the safe range, under the dynamic vehicle load. Comparison of the monitoring results from FBG sensor sensing network are used to unveil the local health condition of Sifangtai Bridge reflected by local strain response.

Thermal modeling of the power transformer to estimate the internal temperature only reflects the winding hot spot to a certain extent. The application of optical fiber sensors to measure transformer internal temperature directly can obtain the true temperature with high accuracy and stability and overcome the shortcomings of traditional electric sensors. This paper analyses the measuring principle of FBG (Fiber Bragg Grating) sensor, and constructs transformer internal temperature measurement platform with FBG temperature sensors, then adopt short-circuit method to simulate the process of winding heat under different load conditions. Finally the measurement of transformer internal temperature is conducted respectively with FBG temperature sensors and thermocouples. Comparison and analysis of the results shows that FBG sensors can effectively measure the internal temperature of the transformer.

Fiber Bragg grating (FBG) sensors have attracted a considerable amount of interest for their superior characteristics. However, the FBG sensors made on bare fibers are easily damaged. For their safe use in engineering, the glass core of optical fibers is coated with softer low modulus protective coatings. A portion of the host material strain is absorbed by the protective coatings when the strain transfers from the host material to the fiber core, and hence only a segment of structural strain is sensed. By introducing the shear modulus of the host material, a novel analytical model is developed for evaluating the sensing strain of the embedded FBG sensors in composite structures based on the strain in a host material. The average strain transfer ratio is deduced to describe the percentage transferred to the optical fiber core from the host material. It is concluded that the shear modulus of the host material influences strain transmission, especially when it is much lower than the modulus of the fiber core. Then, the strain transfer ratio of an optical fiber sensor embedded in a multilayered structure is developed in a similar way. The factors that affect the efficiency of strain transfer on the optical fiber sensor are deduced and discussed in detail based on the theoretical analysis. Finally, the theoretical results are verified through laboratory experimentation with the FBG sensors.

The use of the pultrusion process for the manufacture of fibre reinforced polymer (FRP) composites with embedded fibre optic sensors is discussed. The specific application is the use of smart composite reinforcements for strain monitoring in innovative concrete bridges and structures. The Bragg grating and Fabry-Perot fibre optic sensors are embedded during the pultrusion of FRP rods and the process-induced residual strains are evaluated using these sensors. The behaviour of optic sensors during pultrusion is assessed, and the effect of the embeddment of optical fibres and their surface coatings on the mechanical properties of the composite material is investigated. To verify the operation of the optic sensors embedded in the smart pultruded rods, mechanical tests were conducted and the output of the fibre optic sensors was compared to that of an extensometer. These mechanical tests were performed at room temperature as well as under conditions of low and high temperature extremes. The reliability assessment of the fibre optic sensors further entailed the study of their fatigue and creep behaviour as well as their performance when the rods in which they are embedded are placed in a severe environment (e.g., alkaline solutions) that may simulate conditions encountered in concrete structures wherein the composite rods will be used as prestressing tendons or rebars.Key words: smart composite reinforcements, fibre optic sensors, pultrusion, residual strain, fatigue and creep behaviour, reliability assessment.

Electromagnetic interference (EMI) immune and light-weight, fiber-optic sensor based Structural Health Monitoring (SHM) will find increasing application in aerospace structures ranging from aircraft wings to jet engine vanes. Intelligent Fiber Optic Systems Corporation (IFOS) has been developing multi-functional fiber Bragg grating (FBG) sensor systems including parallel processing FBG interrogators combined with advanced signal processing for SHM, structural state sensing and load monitoring applications. This paper reports work with Auburn University on embedding and testing FBG sensor arrays in a quarter scale model of a T38 composite wing. The wing was designed and manufactured using fabric reinforced polymer matrix composites. FBG sensors were embedded under the top layer of the composite. Their positions were chosen based on strain maps determined by finite element analysis. Static and dynamic testing confirmed expected response from the FBGs. The demonstrated technology has the potential to be further developed into an autonomous onboard system to perform load monitoring, SHM and Non-Destructive Evaluation (NDE) of composite aerospace structures (wings and rotorcraft blades). This platform technology could also be applied to flight testing of morphing and aero-elastic control surfaces.

A review of our recent work on ultrahigh resolution optical fiber sensors in the quasi-static region is presented, and their applications in crustal deformation measurement are introduced. Geophysical research such as studies on earthquake and volcano requires monitoring the earth’s crustal deformation continuously with a strain resolution on the order of nano-strains (nɛ) in static to low frequency region. Optical fiber sensors are very attractive due to their unique advantages such as low cost, small size, and easy deployment. However, the resolution of conventional optical fiber strain sensors is far from satisfactory in the quasi-static domain. In this paper, several types of recently developed fiber-optic sensors with ultrahigh resolution in the quasi-static domain are introduced, including a fiber Bragg grating (FBG) sensor interrogated with a narrow linewidth tunable laser, an FBG based fiber Fabry-Perot interferometer (FFPI) sensor by using a phase modulation technique, and an FFPI sensor with a sideband interrogation technique. Quantificational analyses and field experimental results demonstrated that the FBG sensor can provide nano-order strain resolution. The sub-nano strain resolution was also achieved by the FFPI sensors in laboratory. Above achievements provide the basis to develop powerful fiber-optic tools for geophysical research on crustal deformation monitoring.

On the processing and evaluation of pultruded smart composites