The durability of piezoresistive sensor materials is a core prerequisite for their implementation in structural health monitoring systems. In this work, three piezoresistive materials were subjected to extensive cyclic tensile loadings, and their behaviour was analysed before, after, and during testing. To this end, aluminium specimens were coated with three different industry-grade lacquers, and then piezoresistive materials were applied onto each specimen. Sensors made from carbon black displayed excellent linearity even after tensile loading cycles ($R^2>0.88$). A decline in linearity of all sensors based on carbon allotropes was discovered, whereas the polymer-based sensors improved. Furthermore, their adhesion to the substrate is of great importance. Good adhesion ensures the strains in the underlying structure are correctly transmitted into the sensor materials. Based on contact angle measurements of liquids on sensor materials and on lacquers, their work of adhesion was determined. The findings were verified by tape adhesion tests.

Understanding and predicting damage progression within thin plain-woven CFRP components is an essential issue for scheduling maintenance intervals and structural inspections, and typically require extensive test series. However, uncertainties always remain and result in conservative design and unnecessary downtimes due to the repeated inspections of a healthy structure. SHM can be used to reduce these uncertainties, as it allows to evaluate the condition of a mechanical structure during operation. Numerous SHM methods are developed , that achieve different levels of damage identification but are often investigated at small coupons with non-realistic structural damages and loading conditions on both, structure and sensor. The present research investigates the electrical impedance tomography (EIT) featuring an elastoresistive thin-film sensor to evaluate damage that propagates from a circular hole in a large plate under cyclic tensile-tensile multi-block loading. Applied fatigue loads were increased multiple times up to a total number of two million cycles. During the loading damage initiated at the hole and continuously propagated into the plate. Repeated EIT evaluations of the applied sensor and validating evaluations by means of digital image correlation clearly revealed the robustness of the hardware and the potential of the SHM method for damage evaluation of plain-woven CFRP components.

For many demanding applications of engineering plastics, fracture behaviour under various loading conditions is of prime practical importance. It is well known that fracture properties of plastics are significantly affected by the loading rate, temperature and both local and global stress states. The limitations associated with conventional fracture test methods may, at least in principle, be overcome by the use of appropriate fracture mechanical approaches, which properly account for the temperature and rate dependence of the mechanical behaviour of plastics and should provide geometry-independent fracture toughness values. To provide an additional contribution to this application, fracture tests were performed on both 15- and 20-mm-thick bulk-extruded sheets of a polypropylene random copolymer (PP(RC)) and on four different configurations of their welded joints. The fully ductile fracture range was determined by rate-dependent tests on single CT specimens, and fracture toughness values were derived at the peak loads (JFmax and CTODFmax). Fracture toughness values were determined for stable crack extension based on the J-Δa and/or CTOD-Δa R-curves using single and multiple specimens in terms of various definitions of the crack initiation (J0.2, J0.2BL or δ0.2) toughness values. As expected, both methods revealed distinct differences between the bulk materials and the welded joints. These differences were found to depend on the loading rate, the weld configuration and on the data reduction method (J integral or CTOD).