There has been increasing focus in the area of in-situ structural health monitoring since the advent of embedded nano-composites. This experimental research investigates the structural health monitoring abilities of polymer bonded energetics embedded with a uniformly dispersed but randomly oriented carbon nanotube (CNT) sensing network within the polymer binder. A common formulation of the recent solid propellants consists of ammonium perchlorate (oxidizer) and aluminum powder (combustive fuel)-often shaped using a polymer binder, rather than the older techniques of power pressing. Since this study focuses on the structural health of the material and not its thermal properties, monoclinic sugar crystals were used as a substitute for ammonium perchlorate as it has very similar mechanical properties and is much safer in terms of material handling. Thus, a combination of sugar crystals and aluminum powder bound by a Polydimethylsiloxane (PDMS) binder is fabricated in varying concentrations to simulate actual solid rocket propellants. The main focus of this study lies in characterizing the mechanical and electrical properties of the CNT embedded energetic material through subjecting it under mechanical loads; followed by a detailed observation and study of the real time electro-mechanical response under tension and compression. The addition of carbon nanotubes to the polymer binder, thus translates to a real time sensing technique for detection of multi-scale damage in polymer bonded energetics. The results of this study aim to establish a proof of concept for CNT embedded structural health monitoring systems.

Distributing a carbon nanotube sensing network throughout the binder phase of energetic composites is investigated in an effort for real time embedded sensing of localized heating in polymer bonded explosives (PBXs) through thermo-electromechanical response for in situ structural health monitoring (SHM) in energetic materials. The experimental effort herein is focused on using 70 wt% Ammonium Perchlorate (AP) (solid oxidizer used in solid rocket propellants) crystals embedded into epoxy binder having concentration of 0.1 wt% multi-walled carbon nanotubes (MWCNTs) relative to entire hybrid energetics. Electrical and dielectric properties of neat (i.e. no MWCNTs) energetics and MWCNT hybrid energetics are quantitatively and qualitatively evaluated under localized thermal loading. Electrical and dielectric properties showed variations for both neat energetics and MWCNT hybrid energetics depending on input frequency measurements. Significant thermo-electromechanical response was obtained for MWCNT AP hybrid energetics, providing a proof of concept for thermo-electromechanical sensing for realtime SHM in energetics.

This paper builds on previous work done [1, 2] to explore the effective piezoresistive response of polymer bonded explosive (PBX) materials where the polymer medium is reinforced with carbon nanotubes (CNTs). In the present work, the nanocomposite binder is modeled explicitly as a piezoresistive material whose properties are determined from the nanoscale through a micromechanics based 2-scale hierarchical model connecting the nanoscale to the microscale grain structure. Electromechanical cohesive zones are used to model the interface between the grains and nanocomposite binder in order to characterize interface separation and the resulting piezoresistive effect. The overall microscale piezoresistive effect is measured by using the volume averaged properties of the microscale RVE. The hierarchical framework developed here is used to explore key features of the NCBX microstructure such as the effect of grain conductivity, weight percentage of CNTs used and nanocomposite gage factor.

Traditionally, sensors to be integrated into a structural component are attached to or mounted on the component after the component has been fabricated. This tends to result in unsecured sensor attachment and/or serious offset between the sensor reading and the actual status of the structure, leading to performance degradation of the host structure. This paper describes a novel extrusion-based additive manufacturing process that has been developed to enable embedment of sensors in ceramic components during the part fabrication. In this process, an aqueous paste of ceramic particles with a very low amount of binder content (< 1 vol%) is extruded through a moving nozzle to build the part layer-by-layer. In the case of sensor embedment, the fabrication process is halted after a certain number of layers have been deposited. The sensors are placed in their predetermined locations, and the remaining layers are deposited until the part fabrication is completed. Because the sensors are embedded during the fabrication process, they are fully integrated with the part and the aforementioned problems of traditional sensor embedment can be eliminated. The sensors used in this study were made of sapphire optical fibers of 125 and 250 micro-meters diameter and can withstand temperatures up to 1600 °C. After the parts were built, two different drying processes (freeze drying and humid drying) were investigated to dry the parts. The dried parts were then sintered to achieve near theoretical density. Scanning electron microscopy was used to observe the embedded sensors and to detect any possible flaws in the part or embedded sensor. Attenuation of the sensors was measured in near-infrared region (1500–1600 nm wavelength) with a tunable laser source. Raman spectroscopy was performed on the samples to measure the residual stresses caused by shrinkage of the part and its slippage on the fibers during sintering and mismatch between the coefficients of thermal expansion of the fiber and host material. Standard test methods were employed to examine the effect of embedded fibers on the strength and hardness of the parts. The result indicated that the sapphire fiber sensors with diameters smaller than 250 micrometers are able to endure the freeform extrusion fabrication process and also the post-processing without compromising the part properties.

In this study, the electrochemical performance of Multi-walled Carbon nanotubes (MWCNT) and polyaniline (PANI) composite (PANI/MWCNT) as supercapacitor electrode material was investigated. An improvement in capacitive performance due to the combination of pseudo capacitance and double layer capacitance was observed. A nano-composite was fabricated by polymerizing pseudo-capacitive polyaniline onto the MWCNT surface through the in-situ chemical polymerization approach. Ammonium persulphate (APS) was used as oxidant to polymerize PANI and HCl was used as dopant. Stainless steel thin foil was used as a current collector as well as a flexible back bone. Graphite conductive ink as binder was used to form a conductive paste. Different composition is varied by varying the PANI concentration from 0.1M, 0.3M, and 0.5M to 1M molar concentration. For material characterization, Scanning Electron Microscopy (SEM) was used to characterize surface morphology of the composite. Cyclic Voltammetry and Electrochemical Impedance Spectrometry in three electrodes set up found that 0.1M PANI/MWCNT yields the best electrochemical performance. Two electrodes setup evaluation on 0.1M PANI/MWCNT reviews promising characteristic suitable for device application. The improved electroactivity of the PANI/MWCNT composite is discussed in detail.

The primary purposes of a core in a sandwich composite are to keep the face sheets separated by a fixed distance and to transmit shear stresses. Syntactic foam cores consisting of hollow glass microspheres and resin can form strong, lightweight cores. By underfilling the interstitial space in a packed microsphere bed with a binder, a three-phase syntactic foam is created that has a percolated void network. In a sealed sandwich composite, a void network allows for the entire core of the sandwich composite to be evacuated and mechanically compressed by the exterior pressure. By combining this compression with a heating cycle, it is possible to repair core cracking and core/face sheet interface debonding when a reversible binder is used. Upon cooling, the healed sandwich restores its properties. We examine the relation between the mechanical properties of these sandwich composites and the healing methodologies.