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Juwet T, Luyckx G, Lamberti A, Creemers F, Voet E, Missinne J. Monitoring of Composite Structures for Re-Usable Space Applications Using FBGs: The Influence of Low Earth Orbit Conditions. SENSORS (BASEL, SWITZERLAND) 2024; 24:306. [PMID: 38203168 PMCID: PMC10781290 DOI: 10.3390/s24010306] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/14/2023] [Revised: 12/18/2023] [Accepted: 12/25/2023] [Indexed: 01/12/2024]
Abstract
Fiber Bragg grating sensors (FBGs) are promising for structural health monitoring (SHM) of composite structures in space owing to their lightweight nature, resilience to harsh environments, and immunity to electromagnetic interference. In this paper, we investigated the influence of low Earth orbit (LEO) conditions on the integrity of composite structures with embedded optical fiber sensors, specifically FBGs. The LEO conditions were simulated by subjecting carbon fiber-reinforced polymer (CFRP) coupons to 10 cycles of thermal conditioning in a vacuum (TVac). Coupons with embedded optical fibers (OFs) or capillaries were compared with reference coupons without embedded OFs or capillaries. Embedded capillaries were necessary to create in situ temperature sensors. Tensile and compression tests were performed on these coupons, and the interlaminar shear strength was determined to assess the influence of TVac conditioning on the integrity of the composite. Additionally, a visual inspection of the cross-sections was conducted. The impact on the proper functioning of the embedded FBGs was tested by comparing the reflection spectra before and after TVac conditioning and by performing tensile tests in which the strain measured using the embedded FBGs was compared with the output of reference strain sensors applied after TVac conditioning. The measured strain of the embedded FBGs showed excellent agreement with the reference sensors, and the reflection spectra did not exhibit any significant degradation. The results of the mechanical testing and visual inspection revealed no degradation of the structural integrity when comparing TVac-conditioned coupons with non-TVac-conditioned coupons of the same type. Consequently, it was concluded that TVac conditioning does not influence the functionality of the embedded FBGs or the structural integrity of the composite itself. Although in this paper FBG sensors were tested, the results can be extrapolated to other sensing techniques based on optical fibers.
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Affiliation(s)
- Thibault Juwet
- Com&Sens, 9810 Eke, Belgium; (G.L.); (E.V.)
- Center for Microsystems Technology, Ghent University and Imec, 9000 Ghent, Belgium;
| | | | | | | | - Eli Voet
- Com&Sens, 9810 Eke, Belgium; (G.L.); (E.V.)
| | - Jeroen Missinne
- Center for Microsystems Technology, Ghent University and Imec, 9000 Ghent, Belgium;
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2
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Zeng Y, Chen G, Zhao F, Xu L, Fu Y, Wu C, Shao C, He G, Chen Q, Zhao Y, Sun D, Hai Z. All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass-Ceramic Protective Layer for High-Temperature Applications. ACS APPLIED MATERIALS & INTERFACES 2023; 15:48395-48405. [PMID: 37801478 DOI: 10.1021/acsami.3c10724] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/08/2023]
Abstract
A high-temperature thin/thick-film strain gauge (TFSG) shows development prospects for in situ strain monitoring of hot-end components due to their small perturbations, no damage, and fast response. Direct ink writing (DIW) 3D printing is an emerging and facile approach for the rapid fabrication of TFSG. However, TFSGs prepared based on 3D printing with both high thermal stability and low temperature coefficient of resistance (TCR) over a wide temperature range remain a great challenge. Here, we report a AgPd TFSG with a glass-ceramic protective layer based on DIW. By encapsulating the AgPd sensitive layer and regulating the Pd content, the AgPd TFSG demonstrated a low TCR (191.6 ppm/°C) from 50 to 800 °C and ultrahigh stability (with a resistance drift rate of 0.14%/h at 800 °C). Meanwhile, the achieved specifications for strain detection included a strain sensing range of ±500 με, fast response time of 153 ms, gauge factor of 0.75 at 800 °C, and high durability of >8000 cyclic loading tests. The AgPd TFSG effectively monitors strain in superalloys and can be directly deposited onto cylindrical surfaces, demonstrating the scalability of the presented approach. This work provides a strategy to develop TFSGs for in situ sensing of complex curved surfaces in harsh environments.
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Affiliation(s)
- Yingjun Zeng
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Guochun Chen
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Fuxin Zhao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Lida Xu
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Yanzhang Fu
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Chao Wu
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Chenhe Shao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Gonghan He
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Qinnan Chen
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Yang Zhao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Daoheng Sun
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, PR China
| | - Zhenyin Hai
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361005, PR China
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Luo Y, Sun C, Wei M, Ma H, Wu Y, Chen Z, Dai H, Jian J, Sun B, Zhong C, Li J, Richardson KA, Lin H, Li L. Integrated Flexible Microscale Mechanical Sensors Based on Cascaded Free Spectral Range-Free Cavities. NANO LETTERS 2023; 23:8898-8906. [PMID: 37676244 DOI: 10.1021/acs.nanolett.3c02239] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/08/2023]
Abstract
Photonic mechanical sensors offer several advantages over their electronic counterparts, including immunity to electromagnetic interference, increased sensitivity, and measurement accuracy. Exploring flexible mechanical sensors on deformable substrates provides new opportunities for strain-optical coupling operations. Nevertheless, existing flexible photonics strategies often require cumbersome signal collection and analysis with bulky setups, limiting their portability and affordability. To address these challenges, we propose a waveguide-integrated flexible mechanical sensor based on cascaded photonic crystal microcavities with inherent deformation and biaxial tensile state analysis. Leveraging the advanced multiplexing capability of the sensor, for the first time, we successfully demonstrate 2D shape reconstruction and quasi-distributed strain sensing with 110 μm spatial resolution. Our microscale mechanical sensor also exhibits exceptional sensitivity with a detected force level as low as 13.6 μN in real-time measurements. This sensing platform has potential applications in various fields, including biomedical sensing, surgical catheters, aircraft and spacecraft engineering, and robotic photonic skin development.
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Affiliation(s)
- Ye Luo
- Key Laboratory of 3D Micro/Nano Fabrication and Characterization of Zhejiang Province, School of Engineering, Westlake University, Hangzhou 310030, China
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
| | - Chunlei Sun
- Key Laboratory of 3D Micro/Nano Fabrication and Characterization of Zhejiang Province, School of Engineering, Westlake University, Hangzhou 310030, China
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
| | - Maoliang Wei
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Hui Ma
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Yingchun Wu
- Key Laboratory of 3D Micro/Nano Fabrication and Characterization of Zhejiang Province, School of Engineering, Westlake University, Hangzhou 310030, China
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
| | - Zequn Chen
- Key Laboratory of 3D Micro/Nano Fabrication and Characterization of Zhejiang Province, School of Engineering, Westlake University, Hangzhou 310030, China
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
| | - Hao Dai
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Jialing Jian
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
| | - Boshu Sun
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
| | - Chuyu Zhong
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Junying Li
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Kathleen A Richardson
- The College of Optics & Photonics, Department of Materials Science & Engineering, University of Central Florida, Orlando, Florida 32816, United States
| | - Hongtao Lin
- State Key Laboratory of Modern Optical Instrumentation, College of Information Science and Electronic Engineering, Zhejiang University, Hangzhou 310027, China
- MOE Frontier Science Center for Brain Science & Brain-Machine Integration, Zhejiang University, Hangzhou 310027, China
| | - Lan Li
- Key Laboratory of 3D Micro/Nano Fabrication and Characterization of Zhejiang Province, School of Engineering, Westlake University, Hangzhou 310030, China
- Institute of Advanced Technology, Westlake Institute for Advanced Study, Hangzhou 310024, China
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Cui Y, Li X, Zhang T, Ding W, Yin J. Development of High-Temperature Wire-Grid Thin Film Strain Gauges. SENSORS (BASEL, SWITZERLAND) 2022; 22:7595. [PMID: 36236695 PMCID: PMC9573541 DOI: 10.3390/s22197595] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/01/2022] [Revised: 10/02/2022] [Accepted: 10/03/2022] [Indexed: 06/16/2023]
Abstract
Aero-engine turbine stator blades are often used in harsh environments with high temperatures and high pressure and are prone to fatigue fractures. Real-time and accurate monitoring of blade surface stress and strain is critical to ensure safe operation. In this study, thin-film strain gauges (TFSGs) that can be used in high-temperature environments above 1000 °C were designed and fabricated using a PtRh6 thin film as the sensitive material. The hysteresis effect of the stress transfer upon establishing a thermo-mechanical coupling finite element model of the Inconel718 high-temperature nickel-based alloy equal-strength beam PtRh6 TFSGs was analyzed and the optimal combination of thin-film thickness and longitudinal grid length of wire-grid TFSGs was determined. In order to solve the problem of high-temperature insulation, the insulating properties of a single-layer Al2O3 insulating film, a single-layer ZrO2 insulating film, a double-layer Al2O3/ZrO2 composite insulating film, and a four-layer Al2O3/ZrO2/Al2O3/ZrO2 composite insulating film at high temperature were compared and studied using scanning electron microscopy to analyze the microscopic morphology and composition of the four insulating film structures. The results showed that the four-layer Al2O3/ZrO2/Al2O3/ZrO2 composite insulating film had the best insulating properties at high temperatures. On this basis, an Al2O3/ZrO2/Al2O3/ZrO2 composite insulating film, PtRh6 sensitive layer, and Al2O3 protective film were sequentially deposited on a high-temperature nickel-based alloy equal-strength beam using DC pulsed magnetron sputtering technology to obtain an Inconel718 high-temperature nickel-based alloy equal-strength beam PtRh6 TFSG. Its gauge factor (GF) and temperature coefficient of resistance (TCR) were calibrated, and the results showed that the sensor could be used in harsh environments of 1000 °C. The above results provide new ideas for measuring stress and strain in aerospace under high-temperature and high-pressure environments.
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Affiliation(s)
- Yunxian Cui
- School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China
| | - Xin Li
- School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China
| | - Tenglun Zhang
- Nanjing Kangni Mechanical & Electrical Co., Ltd., Nanjing 210013, China
| | - Wanyu Ding
- School of Materials Science and Engineering, Dalian Jiaotong University, Dalian 116028, China
| | - Junwei Yin
- School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China
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Kefer S, Sauer T, Hessler S, Kaloudis M, Hellmann R. Microstructure-Based Fiber-To-Chip Coupling of Polymer Planar Bragg Gratings for Harsh Environment Applications. SENSORS 2020; 20:s20195452. [PMID: 32977452 PMCID: PMC7583050 DOI: 10.3390/s20195452] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/19/2020] [Revised: 09/19/2020] [Accepted: 09/21/2020] [Indexed: 11/17/2022]
Abstract
This article proposes and demonstrates a robust microstructure-based fiber-to-chip coupling scheme for planar Bragg grating devices. A polymer planar Bragg grating substrate is manufactured and microstructured by means of a micromilling process, while the respective photonic structures are generated by employing a sophisticated single-writing UV-exposure method. A stripped standard single-mode fiber is inserted into the microstructure, which is filled with a UV-curable adhesive, and aligned with the integrated waveguide. After curing, final sensor assembly and thermal treatment, the proposed coupling scheme is capable of withstanding pressures up to 10 bar, at room temperature, and pressures up to 7.5 bar at an elevated temperature of 120 °C. Additionally, the coupling scheme is exceedingly robust towards tensile forces, limited only by the tensile strength of the employed single-mode fiber. Due to its outstanding robustness, the coupling scheme enables the application of planar Bragg grating devices in harsh environments. This fact is underlined by integrating a microstructure-coupled photonic device into the center of a commercial-grade carbon fiber reinforced polymer specimen. After its integration, the polymer-based Bragg grating sensor still exhibits a reflection peak with a dynamic range of 24 dB, and can thus be employed for sensing purposes.
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Affiliation(s)
- Stefan Kefer
- Applied Laser and Photonics Group, Aschaffenburg University of Applied Sciences, Wuerzburger Strasse 45, 63743 Aschaffenburg, Germany; (S.H.); (R.H.)
- Correspondence: ; Tel.: +49-6021-4206-847
| | - Theresia Sauer
- Laboratory for Packaging and Interconnection Technology, Aschaffenburg University of Applied Sciences, Wuerzburger Strasse 45, 63743 Aschaffenburg, Germany; (T.S.); (M.K.)
| | - Steffen Hessler
- Applied Laser and Photonics Group, Aschaffenburg University of Applied Sciences, Wuerzburger Strasse 45, 63743 Aschaffenburg, Germany; (S.H.); (R.H.)
| | - Michael Kaloudis
- Laboratory for Packaging and Interconnection Technology, Aschaffenburg University of Applied Sciences, Wuerzburger Strasse 45, 63743 Aschaffenburg, Germany; (T.S.); (M.K.)
| | - Ralf Hellmann
- Applied Laser and Photonics Group, Aschaffenburg University of Applied Sciences, Wuerzburger Strasse 45, 63743 Aschaffenburg, Germany; (S.H.); (R.H.)
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Imprinted Polymer-Based Guided Mode Resonance Grating Strain Sensors. SENSORS 2020; 20:s20113221. [PMID: 32517127 PMCID: PMC7308864 DOI: 10.3390/s20113221] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/15/2020] [Revised: 06/03/2020] [Accepted: 06/03/2020] [Indexed: 11/16/2022]
Abstract
Optical sensors based on guided mode resonance (GMR) realized in polymers are promising candidates for sensitive and cost effective strain sensors. The benefit of GMR grating sensors is the non-contact, easy optical read-out with large working distance, avoiding costly alignment and packaging procedures. The GMR gratings with resonance around 850-900 nm are fabricated using electron beam lithography and replicated using a soft stamp based imprinting technique on 175 μ m-thick foils to make them suitable for optical strain sensing. For the strain measurements, foils are realized with both GMR gratings and waveguides with Bragg gratings. The latter are used as reference sensors and allow extracting the absolute strain sensitivity of the GMR sensor foils. Following this method, it is shown that GMR gratings have an absolute strain sensitivity of 1.02 ± 0.05 p m / μ ϵ at 870 nm.
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Mattelin MA, Radosavljevic A, Missinne J, Cuypers D, Van Steenberge G. Design and fabrication of blazed gratings for a waveguide-type head mounted display. OPTICS EXPRESS 2020; 28:11175-11190. [PMID: 32403634 DOI: 10.1364/oe.384806] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/10/2019] [Accepted: 02/19/2020] [Indexed: 06/11/2023]
Abstract
In a waveguide-type display for augmented reality, the image is injected in the waveguide and extracted in front of the eye appearing superimposed on the real-world scene. An elegant and compact way of coupling these images in and out is by using blazed gratings, which can achieve high diffraction efficiencies. We report the design of blazed gratings for green light (λ = 543 nm) and a diffraction angle of 43°. The blazed gratings with a pitch of 508 nm and a fill factor of 0.66 are fabricated using grayscale electron beam lithography. We outline the subsequent replication in a polymer waveguide material with ultraviolet nanoimprint lithography and confirm a throughput efficiency of 17.4%. We finally show the in- and outcoupling of an image through two blazed gratings appearing sharp and non-distorted in the environment.
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Multipurpose Polymer Bragg Grating-Based Optomechanical Sensor Pad. SENSORS 2019; 19:s19194101. [PMID: 31547497 PMCID: PMC6806228 DOI: 10.3390/s19194101] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/28/2019] [Revised: 09/17/2019] [Accepted: 09/18/2019] [Indexed: 11/16/2022]
Abstract
Flexible epoxy waveguide Bragg gratings are fabricated on a low-modulus TPX™ polymethylpentene polyolefin substrate for an easy to manufacture and low-cost optomechanical sensor pad providing exceedingly multipurpose application potentials. Rectangular EpoCore negative resist strip waveguides are formed employing standard UV mask lithography. Highly persistent Bragg gratings are inscribed directly into the channel waveguides by permanently modifying the local refractive indices through a well-defined KrF excimer laser irradiated +1/-1 order phase mask. The reproducible and vastly versatile sensing capabilities of this easy-to-apply optomechanical sensor pad are demonstrated in the form of an optical pickup for acoustic instruments, a broadband optical accelerometer, and a biomedical vital sign sensor monitoring both respiration and pulse at the same time.
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