Abstract
This research addresses the challenging task of monitoring the structural integrity of fiber-reinforced composite (FRC) components under complex loading conditions. Ensuring the safety and functionality of these components is critical but economically challenging. Therefore, this study presents an innovative approach using textile-based strain sensors that are cost-effective and structurally compatible with carbon fiber-reinforced plastic (CFRP) components. The investigation includes the systematic electromechanical characterization and comparison of four different sensor materials at the yarn and composite scale in various test scenarios. Cyclic tensile, compression, and bending tests of CFRP specimens are performed and show good reproducibility of sensor signals within the elastic range, with significant agreement observed with applied strain measurement methods, particularly in tensile tests. Although there are minor deviations in compression and bending evaluations, the signals are still meaningful for in-situ detection of complex loading patterns, crack initiation, and structural failure. The study demonstrates that the integration of textile-based sensor yarns allows for continuous structural health monitoring (SHM) of CFRP components under various loading scenarios, including tensile, bending, and especially compressive loads.
Zusammenfassung
Diese Forschungsarbeit befasst sich mit der anspruchsvollen Aufgabe, die strukturelle Integrität von Komponenten aus faserverstärktem Verbundwerkstoff (FVW) unter komplexen Belastungsbedingungen zu überwachen. Die Gewährleistung der Sicherheit und Funktionalität dieserKomponenten ist von höchster Bedeutung, aber wirtschaftlich herausfordernd. Daher präsentiert diese Studie einen innovativen Ansatz unter Verwendung von textilbasierten Dehnungssensoren, die kostengünstig und strukturell mit kohlenstofffaserverstärktem Kunststoff (CFK)-Komponenten kompatibel sind. Die Untersuchung umfasst die systematische elektromechanische Charakterisierung und den Vergleich von vier verschiedenen Sensormaterialien auf der Garn- und Verbundebene in verschiedenen Testszenarien. Zyklische Zug-, Druck- und Biegeversuche an CFK-Proben werden durchgeführt und zeigen eine gute Reproduzierbarkeit der Sensorsignale im elastischen Bereich, wobei insbesondere bei Zugversuchen eine signifikante Übereinstimmung mit den angewandten Dehnungsmessmethoden beobachtet wird. Obwohl es geringfügige Abweichungen bei der Auswertung von Druck- und Biegeversuchen gibt, sind die Signale dennoch aussagekräftig für die In-situ-Erkennung von komplexen Belastungsmustern, Rissinitiierung und Strukturversagen. Die Studie zeigt, dass die Integration textilbasierter Sensorgarne ein kontinuierliches Structural Health Monitoring (SHM) von CFK-Bauteilen unter verschiedenen Belastungsszenarien ermöglicht, einschließlich Zug-, Biege- und insbesondere Druckbelastungen.
Funding source: Deutsche Forschungsgemeinschaft
Award Identifier / Grant number: 287321140
About the authors
Hung Le Xuan studied mechanical engineering at the TUD Dresden University of Technology from 2013 to 2019. Since August 2019, he has been working as a research associate in the research group “Sensor, Measurement and Actuator Technology” at the Institute of Textile Machinery and Textile High Performance Materials Technology (ITM) at TUD. Since October 2023, he is working as research group leader at the ITM. The current research focus is on the development of impact-resistant textile reinforcements and textile-based strain sensors for use in fiber reinforced composites and textile-reinforced concrete. Other research topics are the development of algorithms for automated data evaluation and path planning for robots.
Chokri Cherif received the Ph.D. degree in the field of textile technology in 1998. He has done the postdoctoral studies in 2001. After completing his studies, he worked as an Assistant Professor with RWTH Aachen. In 2005, he accepted the professorship for textile technology at Dresden University of Technolgy. Since 2005, he has held various consultant positions for the EU as well as German research foundations and companies. He is presently the Director of the Institute of Textile Machinery and High Performance Material Technology (ITM), Dresden University of Technolgy. Prof. Cherif holds over 230 national and international patents, and he has published more than 1.500 national and international works in the form of articles in journals, lectures, printed books, and scientific contributions. He served as the President for AUTEX from 2010 to 2013. In 2016, he was awarded the German Future Prize for Technology and Innovation presented by the German President for the joint research project “Fascinating Carbon Concrete–resource-efficient, environment-friendly, slender.” Moreover, he received the Cross of Merit of the Tunisian Republic in 2017, awarded by the President of Tunisia for excellent achievements abroad.
Acknowledgments
Financial support is gratefully acknowledged. We like to thank all the participating companies for their technical support andthe supply of test material as well as all further partners supporting our research work within this application area.
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Research ethics: Not applicable.
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Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission. Hung Le Xuan designed, conducted and evaluated all experiments and wrotethe manuscript. Chokri Cherif provided critical feedback and helped to shape the research, analysis and manuscript.
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Competing interests: The authors state no conflict of interest.
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Research funding: The authors express their gratitude to the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation, https://doi.org/10.13039/501100001659) for the financial support provided in the framework of the Research Training Group GRK 2250 “Mineral-bonded composites for enhanced structural impact safety”, project number 287321140.
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Data availability: The raw data can be obtained on request from the corresponding author.
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