Fully integrated monitoring systems have shown promise in improving confidence in composite materials while reducing lifecycle costs. A distributed optical fibre sensor is embedded in a fibre reinforced composite laminate, to give three sensing regions at different levels through-the-thickness of the plate. This study follows the resin infusion process during fabrication of the composite, monitoring the development of strain in-situ and in real time, and to gain better understanding of the resin rheology during curing. Piezoelectric wafer active sensors and electrical strain gauges are bonded to the plate after fabrication. This is followed by progressive loading/unloading cycles of mechanical four point bending. The strain values obtained from the optical fibre are in good agreement with strain data collected by surface mounted strain gauges, while the sensing regions clearly indicate the development of compressive, neutral, and tensile strain. Acoustic emission event detection suggests the formation of matrix (resin) cracks, with measured damage event amplitudes in agreement with values reported in published literature on the subject. The Felicity ratio for each subsequent loading cycle is calculated to track the progression of damage in the material. The methodology developed here can be used to follow the full life cycle of a composite structure, from manufacture to end-of-life.

In this paper, cure monitoring of a composite laminate is conducted, followed by subsequent structural health monitoring (SHM). A distributed optical fibre (DOF) sensor was embedded between glass fibre fabric plies during manufacture; part of the DOF length was micro-braided using glass fibres, while the remaining length was left 'bare' (as-received condition). In situ and real-time strain measurement during the infusion and curing processes of the laminate was completed. Cure monitoring of composite materials using different fibre orientations, sensor locations, raw materials, and manufacturing methods has been widely studied. However, no consensus was reached due to differences in raw materials, temperature profile, manufacturing method, fibre orientation, and sensor location. The manufactured composite plate was then subjected to repeated loading during a quasi-static four-point bending test, and the strain development along the length of the DOF was recorded. Comparable results were obtained from the micro-braided and bare sections of the DOF, showing the suitability of micro-braided optical fibres for real-time strain monitoring in composite structures. The micro-braiding DOF facilitates handling for automated manufacturing methods and can be used to follow the full life cycle of a composite from fabrication till end-of-life.

In this paper, a passive structural health monitoring (SHM) method capable of detecting the presence of damage in carbon fibre/epoxy composite plates is developed. The method requires the measurement of strains from the considered structure, which are used to set up, train, and test artificial neural networks (ANNs). At the end of the training phase, the networks find correlations between the given strains, which represent the ‘fingerprint’ of the structure under investigation. Changes in the distribution of these strains is captured by assessing differences in the previously identified strain correlations. If any cause generates damage that alters the strain distribution, this is considered as a reason for further detailed structural inspection. The novelty of the strain algorithm comes from its independence from both the choice of material and the loading condition. It does not require the prior knowledge of material properties based on stress-strain relationships and, as the strain correlations represent the structure and its mechanical behaviour, they are valid for the full range of operating loads. An implementation of such approach is herein presented based on the usage of a distributed optical fibre sensor that allows to obtain strain measurement with an incredibly high resolution.

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