ECCOMAS 2024

Numerical simulation of microwires within carbon-fibre composites for structural health monitoring of aerospace components

  • Krach, Wolfgang (CAE Simulation & Solutions)
  • Vonach, Walter (CAE Simulation & Solutions)
  • Malm, Johan (RISE)
  • Johansson, Christer (RISE)
  • Zhukov, Arkady (EHU)

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The usage of carbon-fibre reinforced composites (CFRP) to achieve lightweight structures has further spread throughout the last years in aerospace industry. The lifetime prediction and structural health monitoring (SHM) of these structures is necessary and costly. The usage of magnetic microwires embedded within the CFRP is aimed to enable wireless SHM of the components in service. In our setup, cobalt-rich magnetic microwires covered by a glass coating are used within noncrimp fibre (NCF) composites. These magnetic microwires change their electromagnetic properties while being thermally or mechanically loaded. This change can be detected and measured wirelessly using for instance a handheld high frequency (HF) reader system. To achieve a robust signal, electromagnetic simulations are carried out in parallel to experimental work to understand the physical basics of the interaction between CFRP and the microwires regarding electromagnetic fields. Unidirectional CFRP shows high orthotropy regarding electromagnetic properties. Industrially far more relevant multi-ply multi-directional CFRP shows quasiisotropic electromagnetic behaviour, which is favourable to the accuracy of the measurements. A comparison of attenuation at 2.45GHz shows good correlation between simulations and measurements. To check for practical industrial usability, mechanical simulations (FEM) are performed to ensure that the measuring range covers the generally used allowable strains of up to 0.4%. While accounting for the thermal mismatch in the production process, the orthotropic mechanical material properties of multi-ply CFRP and microwires as well as the rupture strains of the microwires, the simulations show that measuring ranges of up to 1.5% are to be expected. The results indicate that microwires can be used for SHM. Additional work will be carried out to achieve more robust signals and to allow a quantitative signal assessment regarding different failure modes of CFRP. The work is carried out within the Horizon Europe framework (HORIZON-CL5-2021-D5-01) “INFINITE - Aerospace Composites digitally sensorised from manufacturing to end-of-life”