In this study, silica glass, optical fiber Bragg gratings (FBGs) are used for torque-induced strain monitoring in carbon fiber reinforced polymer (CFRP) hollow shafts toward the development of a methodology for structural load monitoring. Optical fibers with gratings are embedded during shaft manufacturing, by an industrial filament winding process, along different orientations with respect to its central axis and surface mounted after production. Experimental results are supported by numerical modeling of the shaft with appropriate boundary conditions and homogenized material properties. For an applied torque up to 800 Nm, the strain sensitivity of an embedded grating positioned along the reinforcing fibers’ direction winded under 55° is in the order of 3.6 pm/Nm, while this value is more than 4× times higher than the other examined orientations. The study also shows that surface-mounted optical fiber Bragg gratings along the reinforcing carbon fibers’ direction perform equally well in monitoring strains in composite shafts under torque.

The increasing prominence of glass-fibre-reinforced plastics (GFRPs) in the wind energy industry, due to their exceptional combination of strength, low weight, and resistance to corrosion, makes them an ideal candidate for enhancing the performance and durability of wind turbine blades. The unique properties of GFRPs not only contribute to reduced energy costs through improved aerodynamic efficiency but also extend the operational lifespan of wind turbines. By modifying the epoxy resin with carbon nanofillers, an even higher degree of performance can be achieved. In this work, graphene nanoplatelet (GNP)-enhanced GFRPs are produced through industrial methods (filament winding) and coupons are extracted and tested for their mechanical performance after harsh environmental aging in high temperature and moisture. GNPs enhance the in-plane shear strength of GFRP by 200%, while reducing their water uptake by as much as 40%.

In the present research work is demonstrated a cross-scale manufacturing approach for the production of multifunctional glass fiber reinforced polymer (GFRP) composite tubes with a purposely redesigned filament winding process. Up until now, limited studies have been reported towards the multiscale reinforcement direction of continuous fibers for the manufacturing of hierarchical composites at the industrial level. This study involved the development of two different multi-walled carbon nanotube (MWCNT) aqueous-based inks, which were employed for the modification of commercial glass fiber (GF) reinforcing tows via a bath coating unit in a pilot production line. The obtained multifunctional GFRP tubes presented a variety of characteristics in relation to their final mechanical, hydrothermal aging, electrical, thermal and thermoelectric properties. Results revealed that the two individual systems exhibited pronounced differences both in crushing behavior and durability performance. Interestingly, for lateral compression the MWCNT coatings comprising a polymeric dispersant minorly affected the mechanical response of the produced tubes. The crashworthiness indicators of the multifunctional tubes displayed a slight 5% variation to the respective reference values, combined with a more ductile behavior. Moreover, regarding the bulk electrical and thermal conductivity values, as well as the Seebeck coefficient factor, the corresponding tubes displayed a variance of 233% and 19% and an opposite semi-conducting sign denoting a p- and n-type character, respectively.