1. Introduction
Composite materials have established themselves as an alternative to metal materials in the construction of structures in multiple areas [
1]. In the aerospace industry, composite materials are primarily used for constructing aerostructures, particularly in the case of aircraft. They exceed 50% of the structural weight of a modern aircraft [
2,
3,
4,
5]. In other industries, such as naval [
9,
10,
11] and transport [
12,
13,
14,
15,
16], the use of composite materials is more limited. This is due to factors such as the recycling of materials made from thermoset resins [
17,
18] and the absence of high-speed manufacturing processes. However, the use of composite materials is trending upwards. The use of composite materials in structures is generally linked to the design of lightweight and optimized structures, a key factor in the aerospace sector and important in other sectors. Applied design philosophies have evolved over the last few decades, moving from structures designed for safe living to structures designed for certain failure, to finally arrive at structures that can withstand damage, the latter philosophy being the one that is applied when you want to build a structurally optimized component. The philosophy of tolerance to harm is based on two key pillars:
- -
Know and quantify the properties of the material, such as: maximum allowable defect size or speed and propagation of the defect, among others. Both fields have been exhaustively studied in recent years for the specific case of composite materials [
19,
20,
21].
- -
Have an inspection and maintenance policy that is capable of detecting the fault before it reaches a critical size [
22,
23].
Normally, maintenance policy was based on a schedule of inspections and preventive actions; although current trends in sectors such as aerospace, wind or railways tend to replace this with maintenance
on condition which allows you to reduce costs significantly. One of the keys to maintenance
on condition [
24] it is the sensorization of the equipment to be maintained, which allows us to know their real situation at all times and to act specifically when necessary. The sensorization of structures is known as SHM (Structural Health Monitoring) [
25,
26]. Its objectives are to detect the levels of stress of the structure, the possible occurrence of failures, the reduction of its life to fatigue or the appearance of overloads, among others [
27,
28,
29]. One of the most widely used monitoring technologies is fiber optic sensors in Bragg gratings (FBGS). They offer several interesting advantages over extensometry technologies: small dimensions, ability to be embedded, simplicity in cabling due to their multiplexability, stability in thermal and load monitoring during the structural life and insensitivity to electromagnetic interference, among others [
30,
31,
32,
33,
34]. The use of FBGS in structures necessitates a comprehensive understanding of the sensor's behavior and its response to various variables, including temperature, humidity, dynamic loads, and the occurrence of loads and/or strains in multiple directions. This last aspect has been studied by multiple authors and was the subject of an experimental study by the same authors of this article [
35,
36,
37,
38,
39]. Have an inspection and maintenance policy that is capable of detecting the fault before it reaches a critical size. Typically, the most commonly used coatings are: polyimide, acrylate and ORMOCER
® [
40,
41,
42,
43]. The importance and influence of the coating on the response of an FBGS sensor lies in the very function it performs, which is to protect the core and the coating from exposure to moisture and abrasion on its surface, preventing the appearance of micro cracks and premature damage to the optical fiber, as well as guaranteeing the phenomenon of reflection according to the
Snell Theory. According to Nath et al [
44], polyimide coatings have the advantage of being resistant to elevated temperatures up to 300ºC and providing reliable results when embedded. In contrast, polyimide is sensitive to humidity. As for acrylate, it is the coating that best protects fiber optics and is immune to humidity, but they are usually critical at temperatures from 100ºC [
44]. The first acrylate coatings consisted of one layer, but due to problems of attenuation induced by microcurvatures or shear retardation, they became two layers. Gloge [
45] He elaborated on this study by stating that the losses produced by microcurvatures are minimized by using an inner (primary) and an outer (secondary) coating with an elastic modulus ratio ten times higher than the secondary versus the primary. In recent years, the ORMOCER
® coating formed by the combination of ceramic and metal has been used. It has a high elastic modulus, is not affected by humidity, provides better radiation protection and is very stable at temperatures above 200ºC [
46,
47,
48].
There are different studies on the influence of coating on embedded FBGS. For example, Pak et al [
49] and Sirkis et al [
50] observed that the thickness and shear modulus of the coating influences the shear–induced strain in the sensor. Roberts et al [
51] concluded that the use of brittle materials as a coating leads to the formation of cracks at low load levels. Other research has studied how bonding between the sensor and the host material influences depending on the type of coating material and bonding agent to improve adhesion [
44,
52]. The most recent studies on coatings are focused on temperature measurement with FBGS. Mishra et al [
53] conducted experiments with different coatings to study how temperature sensitivity varies from the coefficient of thermal expansion. The study comparing coatings is noteworthy for the results obtained at cryogenic temperatures. Sampath et al [
54] performed a comparison of coatings on composite materials under cryogenic conditions for the measurement of temperature and strains, with and without coating, the results of which conclude that the coated sensors have a sensitivity of 48pm/ºC, ten times higher than that of an uncoated FBGS. The use of metallic coatings such as gold and silver has demonstrated a marked improvement in sensor sensitivity to high temperature gradients, with a delay response of 300ms compared to the bare sensor [
55]. It is of interest to mention the study contributed by Weisbrich et al [
56] on shrinkage tests. It analyzes the influence on the output signals of distributed FBGS (Rayleigh type) in concrete structures with the same coatings studied in the present work, whose results show that the ORMOCER
® coating is the one with the least strain losses (< 2%), followed by the polyimide and acrylate coating (< 4 %).
The need to study the influence of transverse strain on the response of the FBGS is justified by some researchers in the scientific community such as R. M. Measures [
57] or in the Review by Luyckx et al [
58]. This work investigates the generation of multiaxial states of strain in a cruciform specimen made of carbon fiber reinforced composite material under different load cases. Three FBG sensors located in the central area of the specimen have been embedded with three types of coating material: polyimide, acrylate and ORMOCER
®. In a previous study, we examined the impact of transverse strain on longitudinal strain measurement for an embedded polyimide-coated FBGS. In this work, a non–negligible measurement error was observed in the tests caused by transverse strain transmitted to the sensor, and
(strain sensitivity factor) was calculated by a proceeding of a uniaxial characterization [
39]. In the present work, a campaign of similar biaxial tests has been done, keeping the longitudinal strain constant and varying the transverse strain, taking as a measurement reference a strain gauge rosette installed in the central area. The tests consisted of four cases of longitudinal strain (500
, 1000
, 1500
and 2000
), simultaneously varying the transverse strain between 0
and 4000
in steps of 500
and keeping the longitudinal strain constant, leaving a time pause in each step to stabilize the sensor. We have applied the equations of Kim et al [
59] correspondent of the
Strain–Optic Theory, for an isotropic sensor a constant temperature. These strain values correspond to those common in composite structures for naval, aeronautics and space use. In addition to calculating for each sensor the influence of transverse strain on the sensor response by analyzing
(variation of the Bragg wavelength) it has been observed how the mechanical behavior of the coating material affects the results.
4. Conclusions
The aim of this study was to evaluate the effect of transverse strains on the response of a FBGS type sensor, embedded in a cruciform specimen of composite material. The sensors analyzed have different coatings (polyimide, acrylate and ORMOCER®) commonly used in structural monitoring. The characterization of this type of sensor is usually carried out with standard uniaxial stress tests. This type of test allows the relationship between the longitudinal strain in the sensor to be obtained and the physical response of it, which is defined through of the sensor (strain sensitivity) by applying a linear regression to the experimentally obtained points. This value depends on the sensor coating material and is considered constant for the entire strain field.
In uniaxial tests, the sensor will be subjected to transverse strain which will depend on the longitudinal strain and the Poisson coefficient, and that it will be equal to. This transverse strain will have the following characteristics:
- -
It will present a fixed value for each longitudinal strain value.
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It will present negative values for each longitudinal strain value.
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It will have low proportions .
The above characteristics do not correspond to the real situation that can be found in a real structure in which it is common, due to complex load states, to have different transverse strain values for the same longitudinal strain value or situations in which the transverse strain may be higher than the longitudinal strain. In laminate composite structures with thin thicknesses, we can assume plane stress hypothesis when are subjected to loads contains in the plane. For this reason, a scientific methodology presented in this article has been carried out to develop different plane stress cases by means of biaxial tests. The results of which have reached the following conclusions:
- -
The response of the sensor to longitudinal strain is significantly influenced by the transverse strain and by the coating material. The influence of transverse strain affects three fundamental parameters of the sensor: the output or response of the sensor and two derived values such as the sensor's (strain sensitivity) and the interpreted value. The influence of transverse strain on the response of the sensor can reach values of up to 46% increase in the signal with respect to the defined reference state (the one with a ratio). This extreme case is observed in a polyimide coated sensor subjected to a ratio. For lower ratios, the influence decreases. It is also observed that the influence on the sensor's output signal is lower in acrylate and ORMOCER® coatings that exhibit very similar behaviors, around 30%.
- -
Regarding the magnitudes derived from sensor
(strain sensitivity) and
interpreted, the influence can reach a 10% increase in the most extreme case
for polyimide and ORMOCER
® coatings. On the other hand, for the acrylate coating, a decrease of 6% in the sensor's
value (strain sensitivity) is observed. This phenomenon may be due to the mechanical nature of the coating material (
Table 1).
- -
A significant hysteresis effect has been observed in the loading and unloading cycles in the acrylate coating, being higher than 150pm for one of the cases, which is logical due to the less rigid nature (
Table 1) of this polymer.
- -
Based on the results obtained, the standardized sensor characterization procedure should be reconsidered, for those sensors working for multiaxial stress states with high ratios where the sensor's (strain sensitivity) could lead to an erroneous interpretation of the results in terms of interpreted .
The experimental results have been compared with the Strain–Optic Theory, observing that the increase in the Bragg wavelength recorded follows a trend contrary to the equations of this theory. It is maintained that among the possible causes may be that the strain field is not completely transferred to the FBGS in traction, but is in out of plane compression. In order to analyze and study this phenomenon, and therefore the response of the sensor, it would be of interest to carry out different studies in which states of deformation are applied to compression or equivalent to confirm or discard this hypothesis experimentally.