Bimodal coaxial fiber sensor for simultaneous strain and temperature sensing for composite manufacturing process

Abstract

Coaxial structured fibers have gained significant attention in sensor applications due to their design flexibility and ability for multifunctionality. However, the complex and thicker structure of a sensor can lead to stress concentration and signal interference when utilized for strain monitoring in composite manufacturing processes. To address this issue, we propose a bimodal coaxial fiber sensor capable of simultaneous temperature and strain measurement during composite cure and strain monitoring, while preserving the mechanical properties of the fabricated composites. To achieve bimodal sensing, we employ a multi-shell structure consisting of a multi-conductive layer with varying concentrations of multiwalled carbon nanotubes and a PEDOT:PSS layer, applied to a creep-enhanced ultra-high molecular weight polyethylene core fiber using a simple dip-coating method. The bimodal coaxial fiber sensor exhibits a high gauge factor (>4.1), stable cyclic tensile response (>1000 cycles), and linear response to stepwise temperature cycles. Moreover, the sensor demonstrates high sensing accuracy (<3% error) in cure strain monitoring and maintains the fracture toughness of the composite (<1% discrepancy) wherein it is embedded. These results confirm the significant potential of the bimodal coaxial fiber sensor for various applications in the composite industry and other fields. © 2024 Elsevier Ltd