Low-cost sensor-based damage localization for large-area monitoring of FRP composites

• Published in: Smart materials and structures 2024-06, Vol.33 (6), p.65042
• Main Authors: Demo, Luke B, Tronci, Eleonora M, Nieduzak, Tymon B, Feng, Maria Q, Aitharaju, Venkat R
• Format: Article
• Language: English
• Subjects: damage localization; FRP composites; large-area; self-sensing carbon fiber; smart material; structural health monitoring
• ISSN: 0964-1726; 1361-665X
• DOI: 10.1088/1361-665X/ad4e7b

In recent years, there has been growing interest in self-sensing structural materials across research and industry sectors. Detecting and locating structural damage typically requires numerous sensors wired to a data acquisition (DAQ) circuit, rendering implementation impractical in real structures. This paper proposes an innovative, cost-effective sensor network for damage detection and localization in fiber-reinforced polymer composites. The innovation encompasses three key elements: (1) utilizing carbon fiber tows within the composite as piezoresistive sensors, eliminating the need for additional foreign sensor devices; (2) introducing a novel sensor layout wherein sensor tow branches with varied resistance values are connected in parallel, reducing the number of connections to the DAQ circuit and cutting manufacturing costs significantly; (3) developing a practical sensor terminal fabrication technique to minimize manufacturing expenses. The proposed design methodology for the branch resistance values is first validated using a demonstration panel. Subsequently, the overall strategy is assessed by conducting impact tests on carbon and glass fiber-reinforced composite specimens. Results validate the sensor’s ability to accurately detect and locate structural damage.