Embedded Strain Sensor

Prepared by:

Short Abstract:

Carbon nanotube polymer composite had

been embedded to glass fibers reinforced
plastic (GFRP) for the structural health
monitoring of the composite material. The
addition of conductive CNT fiber to non
conductive GFRP material aims to enhance its
multifunction
ability.
The
conductive
polystyrene
beads
were
extruded
in
continuous
wire
form
and
used
as
deformation sensor. This polystyrene sensor
wire was embedded into GFRP composite
plate
specimen
and
tested.The
test
specimen's response to mechanical load and
the in situ CNT composites electrical
resistance measurements were correlated for
sensing. Further using Classical laminate
plate theory (CLPT), the strain is correlated to
the dimension of plate and hence strain
mapping of the plate is being done.

Sikil Kumar Singh

Date: 06-04-2016

Integrative Multiscale Engineering Materials and

Systems (iMEMS) Lab,
Department of Aerospace Engineering,
Indian Institute of Science,
Bangalore 560012, India

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Project Summary Sheet

Project Title
Project No.
Project Report No.
Funding Agency Name
Funding Agency Contact
Details
Principal Investigator
Details

(as per project report cover page)

(write IISc in case of OER)
(keep blank in case of OER)
Dr. D. Roy Mahapatra
Associate Professor
Indian Institute of Science
Department of Aerospace Engineering,
Indian Institute of Science,
Bangalore 560012.

Collaborating Agency
Details
Project Duration
Project Status
Total Funding
Type of Project
Subject Areas
Description of Scope of
Project
Project Outcome Achieved
Abstract
Keywords

(also indicate PDC)

(insert short abstract here)

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Content
Abstract

1. Introduction
1.1
1.2
1.3
1.4

Background
Composite Embedded System
Objective
Project Overview Flow chart

5
6
7
8

2. CNT strain gauge

2.1
2.2
2.3
2.4

Strain gauge working principle

Fabrication of MWCNT/CB/epoxy composite ribbon sensor
Preparation of conductive polystyrene continues sensor
Fabrication of sensor embedded composite plate

9
10
11
11

3. Structural Health Monitoring of Composite Plate

3.1 Structural health monitoring implication
3.2 Electronic circuits and calibration
3.3 Sensor Deployment

12
13
17

4. References

19

Abstract
A carbon nano tube with polymer material was used to form a piezo resistive strain sensor for

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structural health monitoring applications. The polymer sensors uses large multi walled carbon
nanotubes which improves the strain transfer, repeatability and linearity of the sensor. The
polymer improves the interfacial bonding between the nanotubes.
Carbon nanotube polymer composite had been embedded to glass fibers reinforced plastic
(GFRP) for the structural health monitoring of the composite material. The addition of
conductive CNT fiber to non conductive GFRP material aims to enhance its multifunction
ability. The test specimen's response to mechanical load and the in situ CNT composites
electrical resistance measurements were correlated for sensing. It is the first time this polymer
sensors is used in composite material for sensing purpose. CNT composites easy to be embed
and does not downgrade the materials mechanical properties. Various incremental loading
steps had been applied to the manufactured specimens in tension, plate bending tests. The
CNT polymer composite worked as a sensor in plate specimen. A direct correlation between
the mechanical loading and electrical resistance change had been established for the
investigated specimens.
Since polymers are often used as the matrix of a composite material, the strain sensitive
matrix can be mixed on a sub material level and used for self strain sensing device as a
whole. Sensors made from conductive polystyrene beads and carbon nanotube polymer
composite materials were used to form continuous strain sensors for structural health
monitoring applications. The conductive polystyrene beads were extruded in continuous wire
form and used as deformation sensor. This polystyrene sensor wire was embedded into GFRP
composite plate specimen and tested. The addition to conductive material to the non
conductive GFRP material aims to enhance its real-time sensing ability. We are reporting for
the first time, the conductive polymer sensor continuously embedded throughout host
composite material for structural health monitoring of composite material. The test
specimens response to mechanical load and the in situ sensors electrical resistance
measurements were correlated for sensing. Various loading steps were applied to the
fabricated specimens in tension mode and direct correlation between the strains and relative
change in resistance was established for investigated specimens. These sensors are the zigzag patterned CNT nanocomposite sensors fabricated on a chemically treated polyethylene
sheet. Chemical treatment enhances its bonding with epoxy-resin based sensors fabricated on
it. The chemical treatment also enhances the bonding with epoxy-resin based matrix in of the
composite laminate. Connectors and printed circuit are provided on polyethylene sheet such
that after embedding in the composite, the rosette sensor gets embedded in the laminate and
the connector emerges out of the sample for electrical connections. Rosette sensor can be
placed at desired layer and at desired location where the strain components are to be
determined. A method to calibrate the embedded sensors in the composite laminate is
demonstrated.

Chapter 1

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Introduction
1.1 Background
Strain sensors are very important in many fields of science and engineering. One of the main
limitations of existing conventional sensors such as gauges is that they are discrete point and
fixed directional sensors, and are separate from the material or structure that is being
monitored hence, not embedded at the material level. It is difficult to implement Raman
spectroscopy for strain measurement in field applications, due to bulky hardware, such as the
measurement of strain in an aircraft wing. There is a need to develop new sensors that can be
embedded into the material and can be used for multidirectional and multiple location
sensing.
The electrical conductivity of the carbon fibers was first used to monitor damage in carbon
fiber reinforced polymers (CFRPs), which could be related to fiber breakage. The electrical
methods have been extensively studied and had been used to study a variety of damage
mechanism, e.g. delamination, matrix cracking, under various loading conditions.
Carbon nanotubes (CNT), due to their electrical conductivity they could be used with nonconductive composite materials in order to enhance their monitoring capabilities. The
addition of several percentage of carbon nanotubes (CNT) to the polymer matrix of
CFRP( also called as doped resin ), lead to a significant increase of the electrical conductivity
of the epoxy matrix. This enabled to fully monitor the structural health of CFRPs and
establish correlation between internal damage and increase in resistance.
Muto et al. [1] first demonstrated that the dispersion of carbon powder to the matrix of GFRP
material can be used for self-diagnosing purposes. In the same work, carbon fiber was used in
the GFRP material for damage monitoring by measuring its change in electrical resistance.
The latter hybrid composite material was not as successive in terms of damage monitoring as
the former, mainly due to the high modulus of the carbon fiber and its brittle nature, when
compared to GFRP material.
Glass fiber reinforced polymers (GFRP) are widely used in the aeronautical and the
automotive industry mainly due to their high specific mechanical properties. During the last
decades, the aerospace industry focus its research in producing multi-functionality materials,
driving design parameters being the weight reduction with increased mechanical properties as
well as monitoring their structural health by means of sensing capability. CNT based polymer
wire fiber is easy to be embedded and does not downgrade the material's mechanical
properties.

1.2

Composite Embedded System

Pros of embedded sensors

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Protect the sensors

Access to interior measurands
Unobtrusive

Cons of embedded sensors

Sensor ingress/egress problematic

Possible detrimental effect on structural integrity
Cannot replace failed sensors

It is possible to embed sensors into composite components during manufacturing to allow

internal interrogation of the material sensors can be based on acoustic waveguide waves,
piezoelectric and optical fibers.
Sensors offering the prospect of continuously monitoring the composite structure at all stages
of its life through fabrication, test qualification and service.
Composite materials with embedded sensors and actuators will be only gain acceptance if the
structural integrity of the composite is not significantly reduced by the presence of inclusion
which are presently significantly larger in diameter then the carbon, Aramide or glass
reinforcing fibers which are typically (8-10 micro meter) diameter, if sensors typically of
(600-900 micro meter) in diameter, are embedded in composite laminates there is an
inevitable disruption of the reinforcing fibers in the vicinity of the fibers sensor.
The nature of this disruption is dependent on both the diameter of the embedded sensors and
the relative orientation of the fibers sensor with respect to neighbouring reinforcing plies. For
example sensing fibers lying parallel to the local reinforcement cause a minimum disruption
provided the diameter is less than half the ply thickness. Reinforcing fibers lying orthogonal
to the sensors are locally deformed creating a resin rich region around the sensors.
In order to accept
1. Produce a minimum perturbation in the distribution of reinforcing fibers
2. Not significantly reduce the mechanical property of composites.
3. Not suffer from excessive attenuation or damage from the embedding process, such that
the sensing technique cannot be applied.
4. Include a suitable means to input and output into the system such system must be robust
and compatible with fabrication process.

In the present work, CNT based strain gauge plate for strain measurement, CNT based
polymer (Polystyrene) fibers will be embedded to GFRP specimen seek simultaneously the
material's response to mechanical load and its sensing capability by means of electrical
resistance change in the polymer wire.
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1.3 Objective
To study Health monitoring especially strain sensing of the GFRP composite through
Embedded sensing by CNT coated polymer (Polystyrene) sensor.

1.4 Project overview flow chart

Strain sensing in GFRP composite
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Material sublevel strain measurement

Conductive polymer (polystyrene) sensor

Composite design, analysis and fabrication with embedded sensor

Mechanical strain sensing

Fig 1.1 Schematics representation of project overview

Chapter 2

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CNT composite strain gauge

strain gauge is an electrical sensor which is used to accurately measure strain in a test
specimen. Strain gauge is effectively a resistor as the strain increase so the resistance
increases. In a basic sense a strain gauge is simply a long wire. Strain gauges usually based
on metallic foil pattern mostly made from copper or aluminium. As the wire in the gauge is
mostly laid from end to end, the strain gauge is only sensitive in that's direction. When an
electrical conductor is stretched within the elasticity it will become thinner longer. As it
becomes thinner and longer its electrical characteristics change. This is because resistance is
a function of both cable length and cable diameter.

2.1 Strain gauge working principle

A strain gauge consists of a foil of resistive characteristics, which is safely mounted on a
backing material. When a known amount of stress in subjected on the resistive foil, the
resistance of the foil changes accordingly. Thus, there is a relation between the change in the
resistance and the strain applied. This relation is known by a quantity called gauge factor.

Where,
GF = gauge factor

= strain
RC = change in resistance after applying load
RC

initial resistance

2.2 Fabrication of MWCNT/CB/epoxy composite

ribbon sensor.
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MWCNTs were obtained from Quantum Materials, Bangalore, India in the form of powder
99% pure with outer diameter 10-20 nm and have a length of 10m. Carbon black powder
with particle diameter less than 10 m is dispersed in an epoxy resin with hardener. This
mixture contains 33% by volume of carbon black [2], with the remaining volume of epoxy
resin and hardener (9:1 by weight). The mixture is stirred mechanically about 100 rpm for an
hour to ensure uniform dispersion of the constituent particles. This mixture of carbon black
and epoxy is used as a host matrix to which MWCNTs are added and sensors are prepared.
MWCNT at (0, 1, 2, 3) weight percentages were dispersed in resin with 5-10ml amount of
ethanol solution are mixed. The MWCNT mixture is undergone mechanical stirring at
constant rate followed by centrifuge mixing at 5000 rpm and sonification to10 minutes. The
process of sonification is one that shoots ultrasonic waves at the sample to improve
dispersion.The mixtures further gone through one more processing cycle. In every stage
probability of mixing particle increased there by getting uniform dispersion of constituent.
After processing the mixture with different weight percentage, the mixture is deposited on a
template in composite lamina. The template made up of Teflon sheet has a dimension
(250x2x0.3mm) to fix on the lamina care must be taken while removing mould without
affecting dimension of pattern. Sample cured under controlled environment at 250C.

2.3 Preparation of conductive polystyrene continues sensor

An cylindrical die cavity of (800) m was filled with carbon black polystyrene beads. The
material was then compressed under predetermined pressure and heated at a constant rate 5 0C
per min, up to maximum temperature of 40 to 1600C. The mixtures kept constant temperature
for 0 to 2h, then extruded in continuous wire form and cooled at room temperature. A major
attention should take in polymer extrusion instability, and the most common cause is a
phenomenon known as melt fracture. Melt fracture is often signaled by surface roughness
and/or surface irregularities. In this paper [3] describe Instabilities can also result from
improperly prepared feedstock, solids conveying issues, insufficient melting or mixing
capacity, barrel temperature fluctuations, lack of uniformity in melt temperature or viscosity
in the die region, improper screw design. The carbon black polystyrene beads are brittle in
nature while extrusion smaller diameter creates melt fracture. Homogeneous coating of
conductive polystyrene with fine MWCNT is not very easy because of its strong aggregating
tendency in surface. MWCNT at (1,2,3) weight percentage CB epoxy host matrix material
filled in cylindrical mould then the polymer wire inserted with controlled rate of 0.1 mm/sec
and rotated at very slow rate. The coating thickness is controlled by mould diameter.

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(a)

(b)

Figure 2.1: Polymer sensor (a) Conductive Polystyrene beads (b) Conductive Polystyrene
wire.

2.4 Fabrication of sensor embedded composite plate

Material system

Glass UD fabric 0.25 mm thickness

Resin system LY556HY + 951 (100:10) with hardener
1 wt% CNT coated polystyrene sensor wire

Fabrication of composite plate involves several processes such as

1. Making template for sensor location
2. Matrix preparation
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3.
4.
5.
6.
7.

Impregnation
Peel ply on both side of plate specimen
Mould transfer
Vacuum packing
Curing

The sample cured by uniform vacuum pressure in room temperature. The final cured sample
trimmed, edge polished as per ASTM D3039 standard [4].

Chapter 3
Structural Health Monitoring of Composite Plate
3.1 Structural health monitoring implication
With a novel idea that structures themselves to be self strain sensing, we embedded the
polystyrene sensor wires as grid inside the composite plate as shown in figure 3.1. This grid
was formed as a matrix of 8 wires, distributed as 4 wires in each direction.

Fig 3.1 GFRP panel embedded with continuous polymer wire

The layer sequence of the composite plate shown in figure 3.1 is [0/0/90/90/0 symmetry],
each layer being a UD glass fibre fabric. PS wires in one direction were woven in third fabric
from top and bottom of the plate, respectively. In all further discussions, wires are referred to
as labelled in figure 3.1.
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Specification of Plate

No of layer
Stacking sequence
Plate dimensions
Plate thickness

: 10
: [02/902/0]s
: 275 x 275 mm
: 2.5 mm

No of sensors embedded into the composite

Wires in 0 ply on middle of 1st and 2nd layer from bottom side.
Wires in 90 ply on middle of 3rd and 4th layer from bottom side.

3.2 Electronic Circuits and Calibration

The sensitivity of each of these wires was investigated by response to a central load under
simply supported plate scheme. . One end of every polystyrene wires was connected to an
external resistor to form a voltage divider circuit. This circuit was implemented to measure
the relative change in resistance values at each load. The external resistors were selected to
have a resistance value comparable with the zero strain resistance of the wire to which they
were connected, in order to have better sensitivity in reading the values. Figure 3.2 shows the
loading and resistance measurement scheme.

(a)

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(b)

(c)

Figure 3.2: (a) Central loading on plate specimen (b) electrical contacts between wires for the
purpose of in-situ RCR values monitoring on the grid, and (c) measurement of voltage
developed across each resistor.

Calibration is necessary to determine the gauge factors of any strain gauge at different strain
levels. Fig. 3.3(a) shows an experimental setup where the composite laminate is simply
supported at two opposite edges using two wedges. A static point load is applied at centre of
the laminate using a tray mounted on a blunt ended spindle. The load is varied by changing
the weights kept on the tray. Tensile and compressive strain is induced by changing the
laminate upside down such that the sensors are placed on top or bottom surface.

(a)

(b)

Figure 3.3: (a) Experimental setup showing simply supported composite laminate with
centrally applied load. Connectors of sensors are connected to DAQ through voltage divider
using ribbon cables (b) Voltage divider circuit diagram

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Varying load changes the strain induced on the strain gauges and nanocomposite sensors.
These strained gauges change their resistances proportional to the load which can be
measured using a voltage divider circuit as shown in Fig. 3.3(b). The voltage divider circuit is
powered by an amplifier. The voltage VS across the standard resistance RS is measured
using a data acquisition system. The resistance of the CNT nanocomposite sensor is given by
V

RC A 1 RS
VS

(1)

where, V A is the applied voltage across the voltage divider. Let VSF be the voltage across
the standard resistance after straining of the laminate. The resistance of the strained CNT
nanocomposite sensor RCF is given by
V

RCF A 1 RS .
VSF

(2)

Using Eq. (1) and (2), the chance in resistance per unit resistance RC / RC is found by

RC RCF RC V A VS VSF

.
RC
RC
VSF V A VS

(3)

Using RC / RC the gauge factor is estimated by

GF

RC / RC

(4)

where is the induced strain in a given direction. Induced strain can be estimated
analytically using laminated plate theories but errors is introduced in estimated gauge factors
due to fabrication and assumed material properties. To avoid errors in calibration of the
sensors, the strain should be determined accurately. Strain determination on the surface is
easier using strain gauge, but difficulty arises when strain is to be estimated at inter laminar
location to calibrate the embedded strain sensors. Also it is not economic to use strain gauges
which are irrecoverable once bonded. Thus a technique is needed to determine correction in
analytically measured strain for a given fabrication technique and assumed material
properties. We present a technique to compensate for these errors in analytical method by
introducing a correction factor in material model determined from the response of the
conventional strain gauges. Classical Laminated Plate Theory (CLPT) is used to estimate
displacements and strain as elaborated in Ref. [11]. The displacement field is given by

u(x, y, z) = -z

w0 ( x , y )
x

(5)

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v(x, y, z) = -z

w0 ( x , y )
y

(6)

w(x, y, z) = w0 ( x , y )

(7)

where u , v and w are the displacement components along x, y and z axis respectively, w0
is the transverse displacement at any point on the mid plane. The strain components are given
by

xx (x, y, z)

u(x, y, z)
2 w0 ( x , y )
= -z
x
x 2

(8)

yy (x, y, z)

2 w0 ( x , y )
v(x, y, z)
= -z
y
y 2

(9)

Levys solution procedure is used to solve the present problem of simply supported plate at
two opposite edges with point load at centre. The solution for transverse displacement w0 is
given by

(10)

Where n / b and b is the width of the laminate. An , Bn , C n and Dn are evaluated

using boundary conditions.

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Also 1, 2, 3, 4 are the roots of the analytical equation which is given by

By using equation (8) and (9) and (10), strain along x-axis and y-axis of plate is calculated,
then gauge factor of each wire along x-axis and y-axis is being calculated by using standard
formula,

GF

RC / RC

For wires parallel to x axis, the gauge factor is given by

Where
b = width of composite plate

Also, for wires parallel to y-axis, gauge factor is given by

Where
a = length of composite plate

3.3 Sensor Deployment

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Deployment of sensor is very important in order to get the map of strain across the plate,
strain mapping is being perform using deployment process. The displacement equation is
given by
W(x, y) = a1x + a2y + a3x2 + a4y2 + a5xy + a6x3 + a7y3 + a8x2y2+ a9xy2 + a10x2y + a11x3y3
So, strain along x axis and y axis is being calculated by using the formula

xx (x, y, z) -z

2 w 0 ( x, y )
x 2

2 w 0 ( x, y )
yy (x, y, z) -z
y 2

(11)

(12)

So after solving equation (10) and (11) we get, strain along x-axis, and y axis are respectively
given by equation (13) and (14).

xx (x, y, z) - 0.55 z a3 0.226875 z a6 0.55 y2 z a8 0.55 y z a10 0.226875 y3 z a11

(13)

yy (x, y, z) - 0.55 z a4 + 0.226875 z a7 0.55x2 z a8 0.55 x z a9 0.226875 x3 z a11

(14)

Hence by using the different value of x, y and z in equation (13) and (14), eight equations can
be formed (four along x- axis and four along y-axis) and by using matrix method the
displacement constant (a1 to a11) can be calculated.

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Where
E1, E2, E3, E4 are strain along x-axis of plate
E5, E6, E7, E8 are strain along yaxis of plate
On using different values of x, y and z in above matrix equation and on taking inverse of
matrix through pivoting by using Gauss- Jordan elimination method, we are able to calculate
the constant (a3, a4, a6, a7, a8, a9, a10, a11).

References
[1] Muto N, Arai Y, Shin SG, Matsubara H, Yanagida H, Sugita M, et al. Compos Sci Technol
2001;61:875-83
[2] Sandeep V Anand and D Roy Mahapatra, Quasi-static and dynamic strain sensing using
carbon nanotube/epoxy nanocomposite thin films Smart Mater. Struct. 18 (2009) 045013
(13pp)
[3] Hans Kramer, Polymer Extrusion Instabilities, Applied Polymer Research, 1999.
[4] ASTM Designation: D3039 Standard Test Method for polymer matrix composite
[5] Ramaratnam A, Jalili NJ. Reinforcement of piezoelectric polymers with carbon
nanotubes: pathway to nextgeneration sensors. Intell Mater Syst Struct 2006;17:199208.
[6] Okabe Y., Yashiro S., Kosaka T., Takeda N. (2000)."Detection of transverse cracks in
CFRP composites using embedded Bragg grating sensors." Smart materials and structures
9(6): 832-838.
[7] Hill, K. O., Meltz G. (1997). "Fiber Bragg Grating Technology Fundamentals and
Overview." Journal of Light wave Technology 15(8): 1263-1276.
[8] Leng J., Asundi A. (2003). "Structural Health Monitoring of Smart Composite Materials
by using EFPI and FBG sensors." Sensors and Actuators A: Physical 103(3): 330-340.

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[9] X. Qing, A. Kumar, C. Zhang, I. Gonzalez, G. Guo and F.-K. Chang, High Speed Hybrid
Piezoelectric/Fiber Optic Diagnostic System for Structural Health Monitoring, Smart
Materials and Structures, Vol.14, No.2, 2005.
[10]Mark Lin and Xinlin Qing, Hybrid Piezoelectric/Fiber-Optic Sensor Sheets-Multiple
Sensors of Different Types Could be Installed On Or In Structures, MFS-31846-1, NASA
Tech Briefs, July, 2004
[11] J.N. Reddy, Mechanics of Laminated Composite Plates and Shells, Theory and
Analysis, 2nd Ed, CRC Press

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