Smart Adhesive Joint with High-Definition Fiber-Optic Sensing for Automotive Applications

Young, Stephen; Penumadu, Dayakar; Foster, Darren; Maeser, Hannah; Balijepalli, Bharati; Reese, Jason; Bank, Dave; Dahl, Jeff; Blanchard, Patrick

doi:10.3390/s20030614

Title: Smart Adhesive Joint with High-Definition Fiber-Optic Sensing for Automotive Applications

Journal Article · 21 January 2020 · Sensors

DOI: https://doi.org/10.3390/s20030614 · OSTI ID:1803994

Young, Stephen ^[1]; Penumadu, Dayakar ^[2]; Foster, Darren ^[2]; Maeser, Hannah ^[2]; Balijepalli, Bharati ^[3];

^[3]; Bank, Dave ^[3]; Dahl, Jeff ^[4]; Blanchard, Patrick ^[4]

Univ. of Tennessee, Knoxville, TN (United States). Tickle College of Engineering; OSTI
Univ. of Tennessee, Knoxville, TN (United States). Tickle College of Engineering
The Dow Chemical Company, Midlands, MI (United States)
Ford Research & Innovation Center, Dearborn, MI (United States)

Structural health monitoring of fiber-reinforced composite-based joints for automotive applications during their manufacturing and on-demand assessment for its durability in working environments is critically needed. High-definition fiber-optic sensing is an effective method to measure internal strain/stress development using minimally invasive continuous sensors. The sensing fiber diameters are in the same order of magnitude when compared to reinforcement (glass, basalt, or carbon fibers) used in polymer composites. They also offer a unique ability to monitor the evolution of residual stresses after repeated thermal exposure with varying temperatures for automotive components/joints during painting using an electrophoretic painting process. In this paper, a high-definition fiber-optic sensor utilizing Rayleigh scattering is embedded within an adhesive joint between a carbon fiber-reinforced thermoset composite panel and an aluminum panel to measure spatially resolved strain development, residual strain, and thermal expansion properties during the electrophoretic paint process-simulated conditions. The strain measured by the continuous fiber-optic sensor was compared with an alternate technique using thermal digital image correlation. The fiber-optic sensor was able to identify the spatial variation of residual strains for a discontinuous carbon fiber-reinforced composite with varying local fiber orientations and resin content.

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Research Organization:: Collaborative Composite Solutions Corporation, Knoxville, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0006926

OSTI ID:: 1803994

Journal Information:: Sensors, Journal Name: Sensors Journal Issue: 3 Vol. 20; ISSN SENSC9; ISSN 1424-8220

Publisher:: MDPI AGCopyright Statement

Country of Publication:: United States

Language:: English

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An active infrared thermography method for fiber orientation assessment of fiber-reinforced composite materials Fernandes, Henrique; Zhang, Hai; Maldague, Xavier Infrared Physics & Technology, Vol. 72 https://doi.org/10.1016/j.infrared.2015.07.021	journal	September 2015
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High resolution optical frequency domain reflectometry for characterization of components and assemblies Soller, Brian J.; Gifford, Dawn K.; Wolfe, Matthew S. Optics Express, Vol. 13, Issue 2 https://doi.org/10.1364/OPEX.13.000666	journal	January 2005
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Distributed Optical Fiber Sensing Based on Rayleigh Scattering Palmieri, Luca The Open Optics Journal, Vol. 7, Issue 1 https://doi.org/10.2174/1874328501307010104	journal	January 2013
Fiber Bragg Grating Sensors for Harsh Environments Mihailov, Stephen J. Sensors, Vol. 12, Issue 2 https://doi.org/10.3390/s120201898	journal	February 2012
A Review of Distributed Optical Fiber Sensors for Civil Engineering Applications Barrias, António; Casas, Joan; Villalba, Sergi Sensors, Vol. 16, Issue 5 https://doi.org/10.3390/s16050748	journal	May 2016
Embedded Distributed Optical Fiber Sensors in Reinforced Concrete Structures—A Case Study Barrias, António; Casas, Joan; Villalba, Sergi Sensors, Vol. 18, Issue 4 https://doi.org/10.3390/s18040980	journal	March 2018
Enhancement of the Performance and Data Processing Rate of an Optical Frequency Domain Reflectometer Distributed Sensing System Using A Limited Swept Wavelength Range Feng, Kunpeng; Cui, Jiwen; Jin, Yihua Sensors, Vol. 18, Issue 10 https://doi.org/10.3390/s18103480	journal	October 2018
Investigation of a Signal Demodulation Method based on Wavelet Transformation for OFDR to Enhance Its Distributed Sensing Performance Feng, Kunpeng; Cui, Jiwen; Dang, Hong Sensors, Vol. 19, Issue 13 https://doi.org/10.3390/s19132850	journal	June 2019

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37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY
42 ENGINEERING
47 OTHER INSTRUMENTATION
Chemistry
Engineering
Instruments & Instrumentation
adhesive
distributed
fiber-optic sensing
joining
on-demand
smart-joint
structural health monitoring

Title: Smart Adhesive Joint with High-Definition Fiber-Optic Sensing for Automotive Applications

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