Polyimide-coated small-diameter optical fiber sensors for embedding in composite laminate structures

Metallic packaging of fiber Bragg grating (FBG) sensors is developed using the ultrasonic welding method. Both polyimide-coated fiber and bare fiber could be bonded well to aluminum alloy substrate using Sn-Bi alloy. Two kinds of metal-packaged FBG sensors, coated FBG and bare FBG, are characterized for studying the thermal sensitivity, strain response, short-term creep, and temporal temperature response. Both FBG sensors showed increasing sensitivity with temperature from -40°C to 80°C. The metal-packaged coated FBG sensor displayed relative strengths in strain stability, repeatability, creep, spectra shape, and temperature response when compared with the bare one. Moreover, the boundaries between optical fiber and metal alloy are intact, and cross-sectional scanning electron microscope micrographs clearly illustrated that metal alloy coated well with the coated and bare fiber.

This article presents a novel method to asses a crack growing/damage event in fibre reinforced plastic, or adhesive using Fibre Bragg Grating (FBG) sensors embedded in a host material. Different features of the crack mechanism that induce a change in the FBG response were identified. Double Cantilever Beams specimens made with glass fibre glued with structural adhesive, were instrumented with an array of FBG sensors embedded in the material and tested using an experimental fracture procedure. A digital image correlation technique was used to determine the presence of the specific phenomena caused by the crack, and to correlate with the FBG sensor. A Material-Sensor model was developed in order to predict the sensor output response under a crack/delamination situation, which can be used as an analysis tool for future application of this measurement technology in more complex structures.

Fiber Bragg Grating (FBG) sensor is a new type of optical sensor that is light in quality, small in volume, easy to achieve distributed measurement, and easy to embed. When FBG sensor technology is introduced to the damage detection of the CFRP shaft, the shortcomings of conventional damage detection technologies, including ultrasonic testing and radiographic testing, can be effectively overcome. Considering the working load, operating environment and life requirements of the CFRP shaft , combined with the relevant national and industry standards for composite material testing, Prepare three CFRP shaft with embedded fiber gratings (non-destructive CFRP shaft, single hole CFRP shaft , double hole CFRP shaft), the hole diameter is 1mm, and the layering of CFRP shaft is ([0 / 90 / 45 / 0 / 0 / 45 / -45 / 0 / -45 / 0 / 90 / 90 / 0 / -45 / 0 / -45 / 45 / 0 / 0 / 45 / 90 / 0 ]). FBG is embedded between 18 and 19 layers, pasted on the surface of CFRP shaft with 10 FBG sensors (named FBG1, FBG2... FBG10). The strain information of the CFRP shaft is obtained through fiber grating to obtain the deformation of the CFRP shaft under a three-point bending load. Each CFRP shaft is loaded 12 times (A1, A2, A3, B1, B2, B3, C1, C2, C3, D1, D2, D3). Through the BP neural network method, the mapping relationship between strain distribution and damage model was established. In the model, the FBG sensor measures the strain of the CFRP shaft and forms the input of the neural network. Combined with the damage situation of the composite material, the learning samples of the network formed. After learning and training, the neural network can damage recognition. To better verify the accuracy of the neural network to distinguish and identify the CFRP shaft non-destructive, single-hole, and double-hole damage patterns. The finite element analysis was used to simulate the damage of three CFRP shafts under the same experimental conditions, and extract the eigenvalues at the same position to form the input of the network, combined with the damage situation of the composite material, constitutes a learning sample of the network. The experiment shows that the CFRP shaft experiment based on BP neural network verifies the reliability of the CFRP shaft damage recognition method. The finite element analysis is used to extract the strain information of CFRP shaft measuring points with different damage modes. The damage position information and strain information were input into the BP neural network. The experimental results are in good agreement with the simulation results, which verifies the accuracy of the BP neural network to distinguish the CFRP shaft non-destructive, single-hole, and doublehole damage patterns.

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.

The monitoring of temperature during operation of lithium ion batteries is crucial for a stable and safe performance of a battery system. However, a major challenge is to obtain exact internal temperature progression upon charge and discharge processes. Though commonly used resistance temperature sensors can give considerably accurate temperature values, they are limited to the application outside of the cell due to the distortion of their signal through induction effects of the applied cell currents, if installed inside the pouch cell and therefore, they are not suitable for in situ measurements. This poses serious problems especially for big cell stacks, as core temperatures for those cells differ greatly from the outer parts and particularly the surface of the cell encasement. Fiber Bragg Grating (FBG) sensors on the other hand, provide data that are unaffected by induction effects as their operating principle is solely based on the reflection of light of certain wavelengths within a glass fiber. However, a specific difficulty is the distinction between temperature and pressure effects, as the reflected signal is sensitive to both. Often times additional tubing around the sensor is needed to eliminate pressure effects or an additional sensor is placed in close proximity, inside or outside, to the FBG-sensor as a reference. The former, however, can affect the cell stack physically acting as a defect spot with unwanted side effects.In our work, we show that a careful calibration of the FBG-sensor can be accomplished, so that both effects can be separated and the FBG-sensor can then be used to gather information not only about temperature but also about volume changes in an operating cell. Therefore, a temperature calibration took place, with the cell being held at a constant SoC. Subsequently, a calibration of the SoC - dependent pressure-induced mechanical deformation was performed at very low C-rate to minimize thermal effects. The so gathered calibration parameters can then be applied to all performed cycling tests, regardless of the C - rate. A calibration routine and mathematical solution to separate the influences of temperature and pressure to receive exact in situ temperature values for a 10 Ah lithium ion battery cell is presented. The calibration method is applied to cycling and rate tests at various C-rates.The results show, that wavelength shifts upon charging and discharging processes are mainly resulting from volume changes of the active cell components, meaning that the FBG – sensor has a very high sensitivity towards pressure changes. With the before mentioned calibration method the impact of mechanical deformation on the FBG - sensor can be subtracted from the raw data and allow for a direct temperature reading. The temperature data correlates with data gathered from commonly used sensors placed on the outside of the pouch cell. Tests with varying discharge rates confirm these results and show, that the method produces precise temperature data even at different C-rates, even though only slow C-rates were applied during calibration.In detailed comparison, the FBG - sensors show a faster response towards temperature changes compared to conventional external temperature sensors, which can be related to the insulating effect of the pouch foil. In case of high discharge rates, we were able to show that the measured temperatures inside of the pouch cell are higher in comparison to the outside ones. Furthermore, SoC - induced changes in pressure measured by two FBG-sensors, which were located at different positions on the cell stack, are almost identical. This indicates that pressure build-up within a pouch cell occurs evenly through the cell stack.

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.

The article describes process of implementation of optical Fiber Bragg Grating (FBG) sensors into the composite wing structure and their behavior during the strength test. The wing is of all-composite construction. The upper and lower skins are made of glass/epoxy composite. The spar caps are made of carbon/epoxy unidirectional composite. Optical fibers were integrated directly into the spar caps and into the adhesive joints. They were oriented in parallel with the main spar axis. The first optical fiber with chain of multiple FBG sensors was integrated into the structure of upper spar cap. Another FBG chain of FBG sensors was located in the adhesive joint of lower spar cap and shear web. The wing was instrumented with strain gages as well. Strain gages were glued to the sides of the spar caps. Static load was produced by a hydraulic actuator. Experimental results from strain gages and FBG sensors were compared with the results of the analytical analysis of the wing.

Fiber Bragg grating (FBG) sensors are excellent transducers for collecting ultrasonic wave signals for structural health monitoring (SHM). Typically, FBG sensors are directly bonded to the surface of a structure to detect signals. Unfortunately, demodulating relevant information from the collected signal demands a high signal-to-noise ratio because the structural ultrasonic waves have low amplitudes. Our previous experimental work demonstrated that the optical fiber could be bonded at a distance away from the FBG location, referred to here as remote bonding. This remote bonding technique increased the output signal amplitude compared to the direct bonding case, however the mechanism causing the increase was not explored. In this work, we simulate the previous experimental work through transient analysis based on the finite element method, and the output FBG response is calculated through the transfer matrix method. The model is first constructed without an adhesive to assume an ideal bonding condition, investigating the difference in excitation signal coherence along the FBG length between the two bonding configurations. A second model is constructed with an adhesive to investigate the effect of the presence of the adhesive around the FBG. The results demonstrate that the amplitude increase is originated not from the excitation signal coherence, but from the shear lag effect which causes immature signal amplitude development in the direct bonding case compared to the remote bonding case. The results also indicate that depending on the adhesive properties the surface-bonded optical fiber manifests varying resonant frequency, therefore resulting in a peak amplitude response when the input excitation frequency is matched. This work provides beneficial reference for selecting adhesive and calibrating sensing system for maximum ultrasonic detection sensitivity using the FBG sensor.

This paper proposes multipoint optical fiber sensing system based on fiber Bragg grating (FBG) sensor array. The low reflectivity FBG sensors having the same Bragg wavelength are connected cascaded in the same fiber line as the sensing elements of optical fiber sensing system. This can increase the monitoring points and reduce manufacturing costs of FBG sensor. To verify the effectiveness, the system simulator based on equivalent circuit model by microwave technology was developed. Simulation result shows that though multi-reflections can be caused by FBG sensors with the same Bragg wavelength connected cascaded in the same line, the effect may become weak as reflectivity of FBG sensors are reduced to 0.02.

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.

Multivariate statistics based damage detection algorithms employed in conjunction with novel sensing technologies are attracting more attention for long term Structural Health Monitoring of civil infrastructure. In this study, two practical data driven methods are investigated utilizing strain data captured from a 4-span bridge model by Fiber Bragg Grating (FBG) sensors as part of a bridge health monitoring study. The most common and critical bridge damage scenarios were simulated on the representative bridge model equipped with FBG sensors. A high speed FBG interrogator system is developed by the authors to collect the strain responses under moving vehicle loads using FBG sensors. Two data driven methods, Moving Principal Component Analysis (MPCA) and Moving Cross Correlation Analysis (MCCA), are coded and implemented to handle and process the large amount of data. The efficiency of the SHM system with FBG sensors, MPCA and MCCA methods for detecting and localizing damage is explored with several experiments. Based on the findings presented in this paper, the MPCA and MCCA coupled with FBG sensors can be deemed to deliver promising results to detect both local and global damage implemented on the bridge structure.

Additive manufacturing (AM) polymers are applied in many branches of the industry due to the possibility of fast and accurate production of elements with various and complex shapes. Fibre Bragg grating sensors (FBG) are widely applied in structural health monitoring (SHM) systems. The main objective of this research is to perform analyses of the influence of embedded FBG sensors on AM polymer elements’ durability. Two polymers (M3 X and M3 Crystal) with different mechanical properties were analysed. The tests were performed on samples with FBG sensors embedded in (different alignment) and attached to the surfaces of the elements. Firstly, the samples were exposed to elevated or sub-zero temperatures under stable relative humidity levels. The strain in the samples was measured using fibre Bragg grating (FBG) sensors. The achieved results allow us to determine the relationships between strain and temperature for both materials and the differences in their mechanical response to the thermal loading. Then, the samples were subjected to a tensile test. A comparison of the tensile strength values was performed for the samples without and with embedded FBG sensors. The samples after the tensile tests were compared, showing differences in the mechanisms of failures related to the polymers and the thermal treatment influence on the material internal structure. Additionally, strain values measured by the FBG sensors were compared to the strain values achieved from the testing machine showing a good agreement (especially for M3 X) and indicating the differences in the materials’ mechanical properties. The achieved results allow us to conclude there is a lack of influence of embedded FBG sensors on the mechanical durability of AM polymers.

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.

In this study, measurements from low-impact velocity experiments including embedded and surface mounted optical fiber Bragg grating (FBG) sensors were used to obtain detailed information pertaining to damage progression in two-dimensional laminate woven composites. The woven composites were subjected to multiple strikes at 2m/s until perforation occurred, and the impactor position and acceleration were monitored throughout each event. From these measurements, we obtained dissipated energies and contact forces. The FBG sensors were embedded and surface mounted at different critical locations near penetration-induced damaged regions. These FBG sensors were used to obtain initial residual strains and axial and transverse strains that correspond to matrix cracking and delamination. The transmission and reflection spectra were continuously monitored throughout the loading cycles. They were used, in combination with the peak contact forces, to delineate repeatable sensor responses corresponding to material failure. From the FBG spectra, fiber and matrix damage were separated by an analysis based on signal intensity, the presence of cladding modes, and the behavior of individual Bragg peaks as a function of evolving and repeated impact loads. This provided an independent feedback on the integrity of the Bragg gratings. A comparison by number of impact strikes and dissipated energies corresponding to material perforation indicates that embedding these sensors did not affect the integrity of the woven systems and that these measurements can provide accurate failure strains.

Fiber Bragg grating (FBG) sensors were used to measure the torsional strain distribution in a second-generation (rare-earth) Ba2Cu3Oy high-temperature superconducting sample tape (SST) at 77 K. Two SST samples were prepared. A slit was fabricated in each sample to allow an optical fiber to be embedded. In the first sample, a 10-mm-long single grating element was inserted into the slit. In the second sample, three grating elements of 10-mm length each were put into the slit. These grating elements were fabricated along a single-mode fiber and could be addressed individually using the wavelength division multiplexing (WDM) technique. Finally, the samples were recoated with a primary and secondary coating to form an embedded sensing system. When the high-temperature superconducting (HTS) tape is subjected to torsion, there is a strain induced in the FBG sensor, which varies the grating period accordingly. It was interrogated using a tunable laser in a WDM scheme. Based on the wavelength shift and the photoelastic properties of the FBG sensor embedded to the HTS tape, the torsional deformation of the HTS tape can be obtained. In this paper, the design and technology requirements to embed the single and WDM FBG sensors into the coated conductors are presented. Initial experiments to measure the torsional strain distribution at 77 K are reported.