Nicolas Lammens

Strain Measurements of Composite Laminates with Embedded Fibre Bragg Gratings: Criticism and Opportunities for Research

Embedded optical fibre sensors are considered for structural health monitoring purposes in numerous applications. In fibre reinforced plastics, embedded fibre Bragg gratings are found to be one of the most popular and reliable solutions for strain monitoring. Despite of their growing popularity, users should keep in mind their shortcomings, many of which are associated with the embedding process. This review paper starts with an overview of some of the technical issues to be considered when embedding fibre optics in fibrous composite materials. Next, a monitoring scheme is introduced which shows the different steps necessary to relate the output of an embedded FBG to the strain of the structure in which it is embedded. Each step of the process has already been addressed separately in literature without considering the complete cycle, from embedding of the sensor to the internal strain measurement of the structure. This review paper summarizes the work reported in literature and tries to fit it into the big picture of internal strain measurements with embedded fibre Bragg gratings. The last part of the paper focuses on temperature compensation methods which should not be ignored in terms of in-situ measurement of strains with fibre Bragg gratings. Throughout the paper criticism is given where appropriate, which should be regarded as opportunities for future research.

Microstructured Optical Fiber Sensors Embedded in a Laminate Composite for Smart Material Applications

Fiber Bragg gratings written in highly birefringent microstructured optical fiber with a dedicated design are embedded in a composite fiber-reinforced polymer. The Bragg peak wavelength shifts are measured under controlled axial and transversal strain and during thermal cycling of the composite sample. We obtain a sensitivity to transversal strain that exceeds values reported earlier in literature by one order of magnitude. Our results evidence the relevance of using microstructured optical fibers for structural integrity monitoring of composite material structures.

Improved accuracy in the determination of flexural rigidity of textile fabrics by the Peirce cantilever test (ASTM D1388)

Within the field of composite manufacturing simulations, it is well known that the bending behavior of fabrics and prepregs has a significant influence on the drapeability and final geometry of a composite part. Due to sliding between reinforcements within a fabric, the bending properties cannot be determined from in-plane properties and a separate test is required. The Peirce cantilever test represents a popular way of determining the flexural rigidity for these materials, and is the preferred method in the ASTM D1388 standard. This work illustrates the severe inaccuracies (up to 72% error) in the current ASTM D1388 standard as well as the original formulation by Peirce, caused by ignoring higher-order effects. A modified approach accounting for higher-order effects and yielding significantly improved accuracy is presented. The method is validated using finite element simulations and experimental testing. Since no independent tests other than the ASTM D1388 standard are available to determine the bending stiffness of fabric materials, experimental validation is performed on an isotropic, homogeneous Upilex-50S foil for which the flexural rigidity and tensile stiffness are related. The flexural rigidity and elastic modulus are determined through both the cantilever test (ASTM D1388) and tensile testing. The results show that the proposed method measures an elastic modulus close to that determined through tensile testing (within 1%), while both the Peirce formulation (+18%) and ASTM standard (+72%) over-estimate the elastic modulus. The proposed methodology allows for a more accurate determination of flexural rigidity, and enables the more accurate simulation of composite forming processes.

Towards micro-structured optical fiber sensors for transverse strain sensing in smart composite materials

We developed a highly birefringent micro-structured optical fiber that, in combination with a fiber Bragg grating sensor, allows measuring transverse strains in reinforced composites. The first generation of this dedicated fiber sensor featured a hydrostatic pressure sensitivity of −15 pm/MPa and yielded a transverse strain sensitivity of −0.16 pm/µε when embedded in a carbon fiber reinforced polymer. The second generation of this sensor has now been fabricated and hydrostatic pressure experiments and FEM simulations show that this generation returns a sensitivity of more than twice that of the first generation. FEM simulations additionally show an increased sensitivity when this sensor is embedded in a reinforced composite, achieving an unprecedented transverse strain sensitivity of 0.29 pm/µε. We explain how the optimized micro-structure yields this record-high sensitivity. In addition we demonstrate the selectivity of the bare fiber sensor, which remains insensitive to temperature changes or axial strain. This sensor can therefore play an important role in the domain of structural health monitoring.

Towards 3D printed multifunctional immobilization for proton therapy: Initial materials characterization

PURPOSE 3D printing technology is investigated for the purpose of patient immobilization during proton therapy. It potentially enables a merge of patient immobilization, bolus range shifting, and other functions into one single patient-specific structure. In this first step, a set of 3D printed materials is characterized in detail, in terms of structural and radiological properties, elemental composition, directional dependence, and structural changes induced by radiation damage. These data will serve as inputs for the design of 3D printed immobilization structure prototypes. METHODS Using four different 3D printing techniques, in total eight materials were subjected to testing. Samples with a nominal dimension of 20 × 20 × 80 mm3 were 3D printed. The geometrical printing accuracy of each test sample was measured with a dial gage. To assess the mechanical response of the samples, standardized compression tests were performed to determine the Youngs modulus. To investigate the effect of radiation on the mechanical response, the mechanical tests were performed both prior and after the administration of clinically relevant dose levels (70 Gy), multiplied with a safety factor of 1.4. Dual energy computed tomography (DECT) methods were used to calculate the relative electron density to water ρe, the effective atomic number Zeff, and the proton stopping power ratio (SPR) to water SPR. In order to validate the DECT based calculation of radiological properties, beam measurements were performed on the 3D printed samples as well. Photon irradiations were performed to measure the photon linear attenuation coefficients, while proton irradiations were performed to measure the proton range shift of the samples. The directional dependence of these properties was investigated by performing the irradiations for different orientations of the samples. RESULTS The printed test objects showed reduced geometric printing accuracy for 2 materials (deviation > 0.25 mm). Compression tests yielded Youngs moduli ranging from 0.6 to 2940 MPa. No deterioration in the mechanical response was observed after exposure of the samples to 100 Gy in a therapeutic MV photon beam. The DECT-based characterization yielded Zeff ranging from 5.91 to 10.43. The SPR and ρe both ranged from 0.6 to 1.22. The measured photon attenuation coefficients at clinical energies scaled linearly with ρe. Good agreement was seen between the DECT estimated SPR and the measured range shift, except for the higher Zeff. As opposed to the photon attenuation, the proton range shifting appeared to be printing orientation dependent for certain materials. CONCLUSIONS In this study, the first step toward 3D printed, multifunctional immobilization was performed, by going through a candidate clinical workflow for the first time: from the material printing to DECT characterization with a verification through beam measurements. Besides a proof of concept for beam modification, the mechanical response of printed materials was also investigated to assess their capabilities for positioning functionality. For the studied set of printing techniques and materials, a wide variety of mechanical and radiological properties can be selected from for the intended purpose. Moreover the elaborated hybrid DECT methods aid in performing in-house quality assurance of 3D printed components, as these methods enable the estimation of the radiological properties relevant for use in radiation therapy.

Fast reconstruction of a bounded ultrasonic beam using acoustically induced piezo-luminescence

We report on the conversion of ultrasound into light by the process of piezo-luminescence in epoxy with embedded BaSi2O2N2:Eu as active component. We exploit this acoustically induced piezo-luminescence to visualize several cross-sectional slices of the radiation field of an ultrasonic piston transducer (f = 3.3 MHz) in both the near-field and the far-field. Simply combining multiple slices then leads to a fast representation of the 3D spatial radiation field. We have confronted the luminescent results with both scanning hydrophone experiments and digital acoustic holography results, and obtained a good correlation between the different approaches.

A micro-computed tomography technique to study the quality of fibre optics embedded in composite materials.

Quality of embedment of optical fibre sensors in carbon fibre-reinforced polymers plays an important role in the resultant properties of the composite, as well as for the correct monitoring of the structure. Therefore, availability of a tool able to check the optical fibre sensor-composite interaction becomes essential. High-resolution 3D X-ray Micro-Computed Tomography, or Micro-CT, is a relatively new non-destructive inspection technique which enables investigations of the internal structure of a sample without actually compromising its integrity. In this work the feasibility of inspecting the position, the orientation and, more generally, the quality of the embedment of an optical fibre sensor in a carbon fibre reinforced laminate at unit cell level have been proven.

Internal strain monitoring in composite materials with embedded photonic crystal fiber Bragg gratings

The possibility of embedding optical fiber sensors inside carbon fiber reinforced polymer (CFRP) for structural health monitoring purposes has already been demonstrated previously. So far however, these sensors only allowed axial strain measurements because of their low sensitivity for strain in the direction perpendicular to the optical fiber’s axis. The design flexibility provided by novel photonic crystal fiber (PCF) technology now allows developing dedicated fibers with substantially enhanced sensitivity to such transverse loads. We exploited that flexibility and we developed a PCF that, when equipped with a fiber Bragg grating (FBG), leads to a sensor that allows measuring transverse strains in reinforced composite materials, with an order of magnitude increase of the sensitivity over the state-of-the-art. In addition it allows shear strain sensing in adhesive bonds, which are used in composite repair patches. This is confirmed both with experiments and finite element simulations on such fibers embedded in CFRP coupons and adhesive bonds. Our sensor brings the achievable transverse strain measurement resolution close to a target value of 1 μstrain and could therefore play an important role for multi-dimensional strain sensing, not only in the domain of structural health monitoring, but also in the field of composite material production monitoring. Our results thereby illustrate the added value that PCFs have to offer for internal strain measurements inside composite materials and structures.

A novel experimental setup for evaluating the stiffness of ankle foot orthoses

ObjectiveThe purpose of this study was the construction of a new semi-automated experimental setup for the evaluation of the stiffness of ankle foot orthoses (AFOs) around an axis aligned to the anatomical ankle joint during the second rocker of the gait. The setup, developed in close collaboration with the orthopedic device company V!GO NV (Wetteren, Belgium), allows measurement of plantarflexion and dorsiflexion in the sagittal plane for a maximal range of motion of 50° (− 25° plantarflexion up to 25° dorsiflexion) in a non-destructive way.ResultsThe mechanical properties of four 3D printed AFOs are investigated, based on the ranges of motion derived from the gait assessment of the patients when they walked with their AFO. The reliability of the stiffness measures was studied by the evaluation of the test–retest repeatability and the intra-tester and inter-tester variability. These studies revealed that the ankle stiffness can be measured with high reliability (ICC = 0.94–1.00). The obtained outcomes indicate that the experimental setup could be applied to measure the ankle stiffness of any topology of AFOs and, in the future, help finding the correlation with the information coming from the gait assessment of the patients.

FE Tool for Drape Modelling and Resin Pocket Prediction of Fully Embedded Optical Fiber Sensor system

This work highlights some of the achievements obtained within the EU FP7 SmartFiber project, aiming to develop a fully embeddable optical fiber sensor system including the interrogator chip. The focus is on resolving issues holding back the industrial uptake of optical sensing technology. In a first section, the development of a placement head for automated lay-down of an optical sensor line (including the SmartFiber interrogator system) during composite manufacturing is discussed. In a second section, the attention is shifted to the occurrence of resin pockets surrounding inclusions such as the SmartFiber interrogator. A computationally efficient F.E. approach is presented capable of accurately predicting resin pocket geometries. Both small (i.e. optical fiber sensors) and large (i.e. the SmartFiber interrogator) inclusions are considered, and the F.E. predictions are validated with experimental observations.