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A Three-Dimensional Surface-Adaptive Stretchable Sensor for Online Monitoring of Composite Materials Curing.
Wei Wang1,2, Bowen Zhang1, Haonan Feng1,2
1School of Electrical Engineering, Tiangong University, Tianjin 300387, China.
ACS Sensors
|October 29, 2024
Summary
New stretchable dielectric sensors enable non-destructive monitoring of composite curing on complex 3D surfaces. These flexible sensors overcome limitations of rigid types, offering enhanced reliability and portability for advanced material manufacturing and deep-sea applications.
Area of Science:
- Materials Science
- Sensor Technology
- Composite Manufacturing
Background:
- Rigid sensors are commonly used for composite curing monitoring but can cause defects like cracks and bubbles.
- These defects negatively impact the mechanical performance and reliability of composite materials.
- Existing rigid sensors lack flexibility, limiting their application on complex 3D surfaces.
Purpose of the Study:
- To develop stretchable dielectric sensors for non-destructive monitoring of composite curing processes.
- To enable embedded monitoring on complex 3D surfaces, overcoming limitations of rigid sensors.
- To enhance the reliability, portability, and accuracy of composite curing monitoring.
Main Methods:
- Design and fabrication of stretchable interdigital dielectric sensors using flexible substrates and electrodes.
- Testing sensor durability through 1000 cycles of bending (0°–180°) and stretching (30% strain).
- Integration of sensors with electronic circuits for real-time data collection and transmission.
- Evaluation of sensor stability after 5 months of atmospheric exposure.
- In-situ monitoring of composite curing on complex 3D surfaces, including the Fendouzhe deep-sea submersible.
Main Results:
- The developed sensors demonstrate excellent durability, withstanding 1000 bending and stretching cycles without performance degradation.
- Sensors conform perfectly to complex 3D surfaces, enabling embedded monitoring.
- Long-term stability was confirmed, with only a 0.1% decrease in unit sensitivity after 5 months of atmospheric exposure.
- High monitoring accuracy was achieved on complex 3D surfaces, comparable to planar equipment (0.4% sensitivity decrease).
- The integrated system is portable, compact, and lightweight, facilitating real-time data acquisition.
Conclusions:
- Stretchable dielectric sensors offer a viable solution for non-destructive, real-time monitoring of composite curing on complex 3D surfaces.
- The technology overcomes the limitations of conventional rigid sensors, improving material quality and reliability.
- The sensors exhibit high sensitivity, accuracy, and long-term stability, suitable for demanding applications like deep-sea submersibles.
