The piezoresistive effect in conductive nanofiller-modified polymer, cementitious, and ceramic composites has immense potential to enable multifunctional properties such as intrinsic self-sensing. To date, much work has been done to study the piezoresistive effect under quasi-static loading. Some work has also been done to study the piezoresistive effect under cyclic loading such as when a piezoresistive patch is adhered directly to an oscillating substrate. However, little-to-no work has been done with regard to general dynamic loading conditions such as strain waves originating from a remote source. This is an important gap in the state of the art for two reasons: One, coupling the self-sensing nature of nanocomposites with general elastodynamics is a possible pathway to enabling the study of full-field dynamics (i.e. using the piezoresistive effect to study internal dynamics as opposed to just surface measurements available via tools such as accelerometers and laser vibrometry). And two, coupling piezoresistive self-sensing with damage detection via vibratory methods could lead to transformative gains in the areas of structural health monitoring (SHM) and nondestructive evaluation (NDE). Therefore, we herein work towards addressing this gap in the state of the art by developing basic knowledge on the relation between elastic strain waves and piezoresistive response. Specifically, an electromagnetic-piezoelectric shaker is used to inject highly-controlled strain waves into a long and slender carbon nanofiber (CNF)-modified epoxy rod. Resistance changes along the length of the rod are then measured as strain waves travel along the length of the rod. It is shown that the measured resistance response closely matches the applied mechanical loading. Results from this preliminary study suggest the establishment of an exciting new field — piezoresistive elastodynamics.

Carbon Fiber Reinforced Polymers (CFRPs) have become an essential part of designing and engineering lightweight rigid bodies, predominantly in the aerospace and automotive industries. Typical epoxy based CFRPs exhibit virtually no plasticity with minimal strain to failure. Although CFRPs have high specific strengths and elastic moduli, the brittle fracture mechanism presents unique challenges in failure detection for the US Army’s vertical lift vehicle components since failure can occur catastrophically. The Army currently uses a “safe-life” interval-based service methodology where components are replaced with regards to a usage spectrum rather than the component’s actual state of structural health. This paper explores a method for solving this problem by investigating the possibility of embedding Terfenol-D particles (∼100 microns in diameter), a magnetostrictive material, into the CFRP’s ply interphase for embedded non-contact, real-time, structural health monitoring. For baseline results, the change in localized (32 mm 2 field of view) magnetic flux was only 0.02% for an applied load of 0–100% of the material’s ultimate tensile strength (UTS). For quasi-static testing procedure on specimen 5714 (15 wt.% Terfenol-D embedded CFRP) on a 0–40% loading interval of the material’s UTS, there was an observed localized (32 mm 2 field of view) magnetic flux gradient of more than 5 mT (4%) with a reversible flux of 100%. For quasi-static testing procedure on specimen 5714 (15 wt.% Terfenol-D embedded CFRP) on a 0–70% loading interval of the material’s UTS, there was an observed localized (32 mm 2 field of view) magnetic flux gradient of more than 3 mT (2%) with a reversible flux of only 25%. Terfenol-D embedded CRFPs have shown promising results for detecting instantaneous strain and degradation levels. Acoustic emission (AE) and X-ray computed tomography (CT) scanning were used to validate the observed results.

Composite materials are ideal for many weight-conscious applications such as aerospace and automotive structures because of their exceptionally high specific properties. However, composite materials are susceptible to complex damage and difficult-to-predict damage growth. This necessitates the application of structural health monitoring (SHM) for in-operation monitoring of damage formation and accumulation. Self-sensing materials are strong candidates for composite SHM because they do not suffer from limitations associated with traditional, point-based sensors. A common approach to self-sensing is the piezoresistive effect in nanofiller-modified materials. To date, work in the area of self-sensing via the piezoresistive effect has focused overwhelmingly on the direct current (DC) response of these materials. This is an important limitation because alternating current (AC) effects inherently provide more information by relating both impedance and phase to damage. Therefore, this work explores the effect of high-cycle fatigue loading on the AC response of carbon nanofiber (CNF)-modified glass fiber/epoxy laminates. Specifically, impedance magnitude and phase angle are both measured through the thickness and along the length of a tension-tension fatigue-loaded specimen with an open-hole stress concentration as a function of load cycle and up to 10 MHz. The collected impedance data is then fit to an equivalent circuit model and correlated to stiffness changes. This means that changes in equivalent circuit behavior can be used to track fatigue-induced softening in self-sensing composites. In light of these promising preliminary results, AC effects appear to have considerable potential for real-time tracking of damage accumulation.

Fibre-reinforced polymer (FRP) composite materials are limited in high temperature applications by the matrix glass transition temperature, T g . At and above this temperature, significant mechanical performance is lost, and degradation processes accelerated. This research explores the use of internal passages, or vascules, within the laminate to carry a coolant fluid, absorbing heat energy and cooling the material. A custom thermal chamber and four-point flexural test fixture were developed to perform in-situ thermo-mechanical testing. Vascular and non-vascular carbon/epoxy specimens were manufactured, containing arrays of four 1.1 mm diameter vascules. Specimens were exposed to temperatures from ambient to 170 °C (T g = 200 °C). Flexural modulus varied little with temperature across all tests. Non-vascular specimens at 170 °C showed a reduction in ultimate strength of 21 % compared to under ambient conditions. The presence of vascules caused a small improvement in flexural modulus and strength, due to displacement of a small number of 0° fibre tows further from the neutral axis as a result of the manufacturing process. At 15 L·min −1 coolant flow, vascular specimens showed full retention of strength compared to non-vascular specimens at ambient, demonstrating the potential mechanical performance benefits.

Shape memory alloys (SMAs) are a class of metallic alloys that possess remarkable characteristics such as superelasticity and shape memory effect. Superelastic SMAs have been considered as fiber in polymer composites due to their ability to recover their deformation upon removal of load, good energy dissipation capacity and impact resistance. Graphene nanoplatelets (GNPs) consists of small stacks of graphene sheets that are two-dimensional. Both sides of atomic lattice of GNPs contact matrix of a composite system and can generate more sites for potential chemical and physical bonding with the host material. Most importantly, graphene sheets and their derivatives can be produced at large-scale for industrial demand at low-cost. This study explores the fabrication of multi-scale reinforced epoxy matrix composites in which GNPs and SMA strands are employed as nano- and micro-scale reinforcements, respectively. First, GNPs are dispersed into a ductile and brittle epoxy matrix to produce GNP/epoxy nanocomposites. To study the effect of GNP content on the behavior of the developed nanocomposite, GNPs are added to the epoxy-hardener mixture at different weight percentages (neat, 0.1%, 0.25%, 0.5%, 1%, and 2%). Uniaxial tensile tests of the developed nanocomposites are conducted under monotonic load up to failure. The optimum GNP content for GNP-reinforced epoxy matrix is determined and used in the fabrication of SMA fiber/epoxy composite. The developed multiscale reinforced epoxy composites are tested under tensile loading and their full-field strain and temperature behavior are monitored and evaluated using a digital image correlation system and an infrared thermal camera.

This article illustrates an approach to develop innovative smart materials based on carbon fiber composites. The proposed approach relies on the use of ultra-light strain sensors that are embedded into the composite and are adopted to monitor in real-time the actual material configuration. Such sensors are composed of electrospun PVDF fibers that exploit piezoelectricity to identify strain and thanks to their extreme lightweight can easily be embedded within the composite layers without affecting the structural integrity. On the other hand, the composite is equipped with a system of internal distributed heaters that can locally and globally vary the composite temperature. Since the adopted epoxy has a considerable temperature-dependent behaviour, it is possible to control its stiffness and thus to control the structural frequencies and damping. By coupling the sensing system with the control system, the structural properties are tuned to match prescribed working conditions, thus optimizing the performance of the proposed smart system. The proposed approach is investigated experimentally by manufacturing prototypes of the smart composite and by performing multiple tests to study the material response and evaluate the obtained performance.

In many structural applications the use of composite material systems in both retrofit and new design modes has expanded greatly. The performance benefits from composites such as weight reduction with increased strength, corrosion resistance, and improved thermal and acoustic properties, are balanced by a host of failure modes whose genesis and progression are not yet well understood. As such, structural health monitoring (SHM) plays a key role for in-situ assessment for the purposes of performance/operations optimization, maintenance planning, and overall life cycle cost reduction. In this work, arrays of fiber Bragg grating optical strain sensors are attached to glass-epoxy solid laminate composite specimens that were subsequently subjected to specific levels of fully reversed cyclic loading. The fatigue loading was designed to impose strain levels in the panel that would induce damage to the laminate at varying numbers of cycles. The objectives of this test series were to assess the ability of the fiber Bragg grating sensors to detect fatigue damage (using previously developed SHM algorithms) and to establish a dataset for the development of a prognostic model to be applied to a random magnitude of fully reversed strain loading. The prognostic approach is rooted in the Failure Forecast Method, whereby the periodic feature rate-of-change was regressed against time to arrive at a failure estimate. An uncertainty model for the predictor was built so that a probability density function could be computed around the time-of-failure estimate, from which mean, median, and mode predictors were compared for robustness.

Energy harvesting from low frequency cyclic motion is possible in a variety of applications, but generating power with piezoelectric stacks at low, off-resonance frequencies is challenging. In this study, Compliant Layer Adaptive Composite Stacks (CLACS) were investigated as a toughened piezoelectric generator to increase efficiency at low frequencies and match the compliance of many commercial devices. CLACS were manufactured with PZT discs, interdigitated epoxy layers of varying thicknesses, and encapsulated in epoxy. Energy production of each CLACS type as a function of compliant layer thickness was characterized. Power amplification of CLACS was modeled assuming discs remain planar, volume of epoxy was conserved, and total epoxy deformations were small. Shear lag theory demonstrated increases in positive in-plane strains induced by external through-thickness compression. This amplified sensitivity of the entire stack to through-thickness compressions, substantially increases power generation capability. Experimental data showed that increases in compliant layer thickness resulted in increased power generation in all loading conditions. The shear lag structural mechanics model showed good correlation with theoretical predictions, assuming small deformation of the compliant layer. In addition to reducing composite stiffness, the CLACS generated 61% more power than conventional stack actuators with the same PZT volume via lateral strain amplification effects.

Conductive nanofiller-modified composites have received a lot of attention from the structural health monitoring (SHM) research community in recent years because these materials are piezoresistive (i.e. they have deformation and damage-dependent electrical conductivity) and are therefore self-sensing. To date, the vast majority of work in this area has utilized direct current (DC) interrogation to identify and/or localize damage. While this approach has been met with much success, it is also well known that nanofiller-modified composites possess frequency-dependent electrical behavior. This behavior can be roughly modeled as a parallel resistor-capacitor circuit. However, much less work has been done to explore the potential this frequency-dependent behavior for damage detection. To this end, the work herein presented covers some preliminary results which leverage high-frequency electrical interrogation for damage detection. More specifically, carbon nanofiber (CNF)/epoxy specimens are produced and connected to an external inductor in both series and parallel configurations. Because the CNF/epoxy electrically behaves like a resistor-capacitor circuit, the inclusion of an inductor enables electrical resonance to be achieved. Changes in resonant frequency are then used for rudimentary damage detection. These preliminary results indicate that the potential of SHM via the piezoresistive effect in nanofiller-modified composites can be considerably expanded by leveraging alternating current (AC) interrogation and resonant frequency principles.

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.

To continue to meet spacecraft systems ever increasing thermal management requirements, new control methods need to be developed. While advances in metamaterials have provided the ability to generate materials with a broad range of material properties, relatively little advancement has been made in the development of adaptive metamaterials. This paper is focused on the development of a thermal management metamaterial that enables the active and passive control of a metamaterial’s thermal conductance. This variable conductivity is achieved through the application of internally or externally applied loads that induce internal contact resulting in changes in the conductive path length and the effective conductive area. This capability enables active or passive control of a metamaterial’s effective thermal conduction through the application of mechanical and thermal strain. Passively applied thermal strains can be used to design a highly nonlinear material thermal conductivity as a function of temperature. Actively, this can be used to precisely control the temperature of an interface through dynamically changing the instantaneous heat flux through the metamaterial. This work expands on the field of thermal switches by enabling a non-binary configuration where the initial air gap is slowly closed as contact sequentially introduced into the metamaterial. As internally or externally developed loading is applied, contact is introduced with an increasing contact area until full contact is achieved. This intermediate step of partial contact enables unique design capabilities that enable highly nonlinear thermal conductivity as a function of temperature as well as stability regions that allow passive thermal control. An example metamaterial was developed and evaluated to quantify the potential of this concept. The specific metamaterial configuration assessed in this paper uses offset flat and curved copper plates that are connected at the edges of the plate using a low conductivity epoxy. To evaluate the metamaterial performance, the stiffness and thermal conductivity are calculated as a function of the resulting contact area and the required applied loading. This work is focused on determining the potential of this metamaterial concept by evaluating this initial concept confirmation to establish the magnitude of the thermal conductance change, and the design of the conductivity change a function of applied loading.

This paper presents a simulation-based study to investigate the damping properties of a novel piezocomposite, consisting of piezoelectric fiber and epoxy reinforced with randomly orientated double walled carbon nanotubes (DWCNT), termed as piezoelectric fiber nano reinforced composite (PFNRC). Authors have observed that the past research dealt with the effect of aligned single walled carbon nanotubes (CNT) on active damping of piezoelectric composite in extension mode (e 13 and e 33 ). It is known from the past research that DWCNT inclusions improve the passive damping of a composite. Therefore, the authors use DWCNT inclusions to study the active-passive damping of the piezoelectric composite, in this article. The random orientation of the DWCNT is considered to replicate the physical composite as it known that aligning CNTs in a single direction is not feasible due to fabrication constraints. A multistep homogenization method involving Method of Cells (MOC) is employed to obtain effective properties of PFNRC. A modified 3D-MOC is used to obtain the effective properties of epoxy matrix with DWCNT inclusions (DWCNT-epoxy), considering the effect of nano particle agglomeration. A 2D-MOC is then implemented with long fiber PZT as the active material and DWCNT-epoxy as the matrix. This procedure is followed for computing the effective material properties of extension (e 33 ) as well as shear (e 15 ) mode of PFNRC, when DWCNT inclusions are added into the epoxy matrix at different weight percentages. The constitutive equations are derived with the help of Maple and simulated in MATLAB. These results are used to compare the active-passive damping performance of the composites using a single degree of freedom damping model, employing Newmark’s numerical integration method. The active damping performance of the composites is evaluated by varying the displacement and velocity gains in a negative feedback system. The main focus of the study is to find the most efficient operating mode of the proposed composite for damping of structural vibrations.

The paper begins with a brief overview of historical building coverings. Thermadapt™ thermally adaptive buildings are introduced as a completely new class of shingles, siding and roofing. These elements physically change shape in response to thermal loading. In hot weather with high solar loading, the panels curl up and away from the building. As the temperature cools and the sun sets, the Thermadapt™ elements lie close to the building. In cool temperatures, the elements lie flat agains the building transferring solar energy. In extremely cold temperatures, high convexity inherently forms in the elements, forming a pocket of trapped dead air which forms a highly effective layer of insulation. Thermadapt™ elements are analytically modeled using Classical Laminated Plate Theory (CLPT). Although Thermadapt™ elements may use materials like shape memory alloys, cost concerns drive the use of coefficient of thermal expansion mismatch as the basic driving mechanism. A series of experiments were performed on a variety of Thermadapt™ elements using high CTE mismatch pairs of structural materials including graphite-epoxy and aluminum and Invar and aluminum pairings. Analytical estimates are shown to predict the performance of the Thermadapt™ panels with great accuracy with curvature levels measured and predicted in excess of 5 deg/m/°C. Analytical predictions using CLPT employed a lateral constraint, driving lateral curvature, κ y , to zero by the use of stiff lateral constraint mechanisms like edge rolls and lateral corrugations. This constraint was shown to increase deflections by roughly 33% over the unconstrained elements which were simply allowed to encounter equal curvatures in x and y directions, or “doming.”

Active Fiber Composites (AFCs) are piezoelectric devices comprised of long cylindrical fibers, typically made of ceramic lead zirconate titanate (PZT), embedded in an epoxy polymer. AFCs use interdigitated electrodes to produce electric field lines parallel to the fibers (33-mode) rather than across the diameter, exploiting the stronger out-of-plane electromechanical coupling. Nonlinear piezoelectric and dielectric terms and non-uniform poling are often neglected in modeling AFCs due to the added complexity, however including the terms improves accuracy for strong electric fields and where the electrode geometry causes non-uniform electric fields. For that reason, a new finite element model of the AFC is developed which includes the effect of nonlinearities in piezoelectric strain constants and electric permittivity due to a non-uniform applied electric field resulting from two sets of interdigitated electrodes. The methods used to apply the nonlinear constitutive equations and poling are described. A comparison of the AFC response with linear and nonlinear material properties, with non-uniform poling, is shown for increasing applied electric fields. The difference in AFC response illustrates the necessity to include Rayleigh Law terms and non-uniform poling in the model.

Designing devices made from epoxy-based shape memory polymers is difficult because few material behavior parameters are available for these materials in the rubbery/shape changing region. This work examines the rubbery state, greater than 20° C above the glass transition temperature (Tg), as an elastomeric regime suited to characterization with simple tension and planar tension experiments. Differential scanning calorimetry (DSC) results show a 70° C Tg, which agrees with prior research. Simple tension experiments at 100° C exhibited nonlinear elastic behavior, and finite element analysis (FEA) agreed with the constitutive behavior exhibited in the experiments. Planar tension experiments exhibited novel results. The stress/strain response was sigmoidal with a significant plateau in stress followed by rising stress to failure. The typical 10:1 gage width/gage length ratio seemed to over constrain the material. The strain to failure is small, and suggests the material behavior is a hybrid of elastic and hyperelastic behavior.

An experimental characterization of nanocomposite strain and damage sensing in support of development of CNT-polymer nanocomposites for structural health monitoring (SHM) applications was conducted. As such, effort here is focused towards examining the piezoresistive behavior of poly(dimethyl-siloxane) (PDMS) and epoxy filled with acid treated single walled carbon nanotubes (COOH-SWNTs) under quasi-static compression and tension. Precision LCR Meter with two terminal method, in conjunction with mechanical testing and data acquisition system were used to measure instantaneous resistance values. Given the emphasis on SHM applications which correlate changes in electrical resistivity to deformation and damage, 0.1 wt% COOH-SWCNTs concentration below the nanocomposite electrical percolation threshold was considered for PDMS and epoxy. Measurements confirmed the onset of damage prior to noticeable effects in the stress-strain response. The resistance measurements were able to both detect strain for PDMS nanocomposites and damage initiation and provide continuous assessment of the damage state between damage initiation events for epoxy nanocomposites. Digital Image Correlation (DIC) System was used to observe the crack propagation on notched epoxy nanocomposite compact tension samples.

Incorporation of multifunctionality to fibre reinforced polymer composite materials delivers many benefits. One example includes improved longevity of components through increasing permissible temperatures of operation, which could be achieved via in-situ cooling. As the temperature of composite components approaches the glass transition temperature (T g ) of the matrix, thermal stress induced ageing greatly increases [1], [2], thus the incentive for integrated cooling. In order to assess the damage, which could be caused by exposure to elevated temperatures, isothermal ageing was performed at a temperature 15°C lower than the materials T g (2200 hours at 110°C). Material used in this study is a carbon/epoxy prepreg system (Gurit, SE70), with a T g of 126°C when cured at 110°C. Results have shown a significant drop in Short Beam Shear (SBS) Strength starting after exposure for 1700h and increase in fibre bridging seen in mode I Double Cantilever Beam (DCB) testing. Fracture surface analysis using SEM indicated that fibres were generally less well bonded to the matrix, with visible changes began occurring as early as 1000h exposure. These results indicate that extended exposure of a material at near T g temperatures has a detrimental effect on material properties. To mitigate against this phenomenon, a series of tests were performed on SBS and DCB specimens in a raised temperature (110°C) environment, which incorporated in-situ cooling. The specimens were placed in an oven at 110°C and were cooled down to a constant temperature of 60°C via the internal vascular cooling arrangement. Further testing is underway to assess the inhibition of ageing and maintenance of the original composite material by active cooling using embedded vascular networks.

Highly cross-linked polyurethanes have a high elastic modulus and creep resistance, but they undergo a brittle fracture below the glass transition temperature. Unfortunately, a large number of glassy polyurethanes are prone to brittle fracture without undergoing large elastic deformations; in particular, brittle failure is common under conditions such as low temperature and high strain rates. While the rigidity in polymers is required for practical applications, the lack of resistance against crack propagation is essential to avoid catastrophic failures. The toughening of polymers is a crucial aspect of improving the strength and ductility at specific temperatures and deformation rates. One method that has shown promise in recent years is the creation of local regions of reduced modulus that absorb strain energy and toughen the polymer. For instance, rubbers are typically added to epoxy which phase separate upon polymerization and create local elastic regions that significantly toughen the polymer. In this study, a variety of two-phase transparent polyurethanes in the form of single inclusions is designed to study the toughening mechanism of the local regions of reduced modulus with an embedded crack. Synthesized heterogeneous polyurethanes show a transition from brittle to ductile behavior in addition to a drastic increase in the maximum load that the polymer can withstand. Compact tension experiments demonstrate that a small reduction in the inclusion’s Young’s modulus (∼10%) leads to an increase in the toughness by factor of 7 (∼700%). Moreover, digital image correlation is performed to map the strain distribution around the crack in order to visualize possible toughening mechanism. Comparison between the induced strain field in samples with inclusion and samples without inclusion reveals an efficient toughening mechanism of the polymers.

Traditional composite materials invented to be used in structures with the purpose of high load-bearing with excellent in-plane properties. Continuous fiber reinforced composites are one of the mostly used categories of advanced composites. This class of composites has gained a lot of attention due to their light-weight and decent mechanical properties. However, additional material design is required to tune both mechanical and structural properties of these composites. Since the load transfer between reinforcement phase and polymer matrix happens at the interfacial region, a better interphase might result in a composite with higher vibration damping. In this study, a gradient interphase between carbon fiber and polymer matrix has been created by using ZnO nanowires to engineer the damping loss factor of the carbon fiber composites. For the growth of ZnO nanowires on the carbon fabric, low temperature hydrothermal reaction has been used. Then the carbon fabrics with ZnO nanowires were infiltrated with a low viscosity epoxy using vacuum assisted resin transfer molding technique. The stiffness and structural damping of the composite were examined using dynamic mechanical analysis. The results show that the damping properties of hybrid composites using ZnO nanowires are enhanced compare to the bare carbon fabric composites. Since the growth of ZnO nanowires is a tunable process, the length, diameter and aspect ratio of the nanowires and consequently the architecture of the interphase can be tailored for the desired vibration damping in the system. Thus, the hybrid composites with ZnO nanowire interphase can be used to enhance the energy dissipation in a structural system.

Utilizing conductivity changes to locate matrix damage in glass fiber reinforced polymers (GFRPs) manufactured with nanocomposite matrices is a promising avenue of composite structural health monitoring (SHM) with the potential to ensure unprecedented levels of safety. Nanocomposites depend on the formation of well-connected nanofiller networks for electrical conductivity. Therefore, matrix damage that severs the connection between nanofillers will manifest as a local change in conductivity. This research advances state of the art conductivity-based SHM by employing electrical impedance tomography (EIT) to locate damage-induced conductivity changes in a glass fiber/epoxy laminate manufactured with carbon black (CB) filler. EIT for damage detection is characterized by identifying the lower threshold of through-hole detection and demonstrating the capability of EIT to accurately resolve multiple through holes. It is found that through holes as small as 3.18 mm in diameter can be detected, and EIT can detect multiple through holes. However, sensitivity to new through holes is diminished in the presence of existing through holes unless a damaged baseline is used. These research findings demonstrate the considerable potential of conductivity-based health monitoring for GFRP laminates with conductive networks of nanoparticles in the matrix.