Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring
Embedding fiber optic sensors in critical components is a key step for real-time monitoring of structural conditions during service and supporting autonomous system operations. Successful integration of these sensors necessitates effective interfacial bonding between the fiber and matrix, good integ...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424028539 |
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| author | Xinchang Zhang Joshua Daw Charles Payne Bibo Zhong Austin Fleming Zilong Hua Jorgen Rufner |
| author_facet | Xinchang Zhang Joshua Daw Charles Payne Bibo Zhong Austin Fleming Zilong Hua Jorgen Rufner |
| author_sort | Xinchang Zhang |
| collection | DOAJ |
| description | Embedding fiber optic sensors in critical components is a key step for real-time monitoring of structural conditions during service and supporting autonomous system operations. Successful integration of these sensors necessitates effective interfacial bonding between the fiber and matrix, good integrity and functionality of the embedded sensors, robust mechanical strength of the matrix materials, and the ability to retain these properties during transient thermal and stress events. This study demonstrates the encapsulation of fused silica optical fibers in stainless steel and nickel through the electric field-assisted sintering (EFAS) process. Copper-coated and gold-coated single mode optical fibers were embedded under different EFAS conditions. The resulting components with embedded sensors were evaluated using advanced microscopy and optical frequency domain reflectometry (OFDR) to assess the aforementioned critical aspects of embedding. The results indicate that both copper- and gold-coated fibers can be successfully embedded in stainless steel and nickel with good fiber integrity and fiber-matrix bonding. Samples fabricated under optimal conditions passed helium leak testing, confirming effective interfacial bonding. Microstructural characterization revealed excellent fiber-matrix adhesion and interdiffusion of elements across the interface. The functionality of the embedded fibers was evaluated through OFDR scans, which revealed signal insertion loss of 0.43–0.52 dB for nickel samples and 0–0.75 dB for stainless steel samples at the embedding sites. Additionally, the embedded fibers underwent cyclic thermal treatment between 500 °C and 700 °C. The fibers maintained good integrity and interfacial characteristics, demonstrating their ability to survive cyclic thermal events for sensing in harsh environments. |
| format | Article |
| id | doaj-art-e65c057e1572402291fc96a333e5b64e |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-e65c057e1572402291fc96a333e5b64e2025-01-19T06:25:12ZengElsevierJournal of Materials Research and Technology2238-78542025-01-01341531Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoringXinchang Zhang0Joshua Daw1Charles Payne2Bibo Zhong3Austin Fleming4Zilong Hua5Jorgen Rufner6Corresponding author.; Idaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesIdaho National Laboratory, Idaho Falls, ID, 83415, United StatesEmbedding fiber optic sensors in critical components is a key step for real-time monitoring of structural conditions during service and supporting autonomous system operations. Successful integration of these sensors necessitates effective interfacial bonding between the fiber and matrix, good integrity and functionality of the embedded sensors, robust mechanical strength of the matrix materials, and the ability to retain these properties during transient thermal and stress events. This study demonstrates the encapsulation of fused silica optical fibers in stainless steel and nickel through the electric field-assisted sintering (EFAS) process. Copper-coated and gold-coated single mode optical fibers were embedded under different EFAS conditions. The resulting components with embedded sensors were evaluated using advanced microscopy and optical frequency domain reflectometry (OFDR) to assess the aforementioned critical aspects of embedding. The results indicate that both copper- and gold-coated fibers can be successfully embedded in stainless steel and nickel with good fiber integrity and fiber-matrix bonding. Samples fabricated under optimal conditions passed helium leak testing, confirming effective interfacial bonding. Microstructural characterization revealed excellent fiber-matrix adhesion and interdiffusion of elements across the interface. The functionality of the embedded fibers was evaluated through OFDR scans, which revealed signal insertion loss of 0.43–0.52 dB for nickel samples and 0–0.75 dB for stainless steel samples at the embedding sites. Additionally, the embedded fibers underwent cyclic thermal treatment between 500 °C and 700 °C. The fibers maintained good integrity and interfacial characteristics, demonstrating their ability to survive cyclic thermal events for sensing in harsh environments.http://www.sciencedirect.com/science/article/pii/S2238785424028539Fiber optic sensorEmbedded sensorOFDRHigh temperatureHealth monitoringSintering |
| spellingShingle | Xinchang Zhang Joshua Daw Charles Payne Bibo Zhong Austin Fleming Zilong Hua Jorgen Rufner Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring Journal of Materials Research and Technology Fiber optic sensor Embedded sensor OFDR High temperature Health monitoring Sintering |
| title | Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| title_full | Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| title_fullStr | Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| title_full_unstemmed | Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| title_short | Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| title_sort | electric field assisted embedding of fiber optic sensors in structural materials for structural health monitoring |
| topic | Fiber optic sensor Embedded sensor OFDR High temperature Health monitoring Sintering |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424028539 |
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