Carbon fiber-reinforced polymer (CFRP) composites are widely used in aviation thermal insulation layers due to their high strength-to-weight ratio and excellent high-temperature performance. However, challenges remain regarding their structural integrity and durability under extreme conditions. This study first employed finite element simulation to model the damage evolution of CFRP laminated plates under axial tensile loads and their thermal decomposition behavior in high-temperature environments, providing a theoretical reference. Subsequently, experimental research was conducted on CFRP laminated plates embedded with fiber Bragg grating (FBG) sensors. In the tensile tests, FBG sensors accurately monitored the entire process from elastic deformation to damage propagation and eventual failure. In the high-temperature tests, despite a 75% reduction in tensile strength, FBG sensors effectively monitored damage evolution. Conclusively, the results demonstrate that FBG sensors possess reliable monitoring capabilities under complex conditions, making them a promising solution for the long-term structural health monitoring of aviation thermal insulation materials and paving the way for future developments in this area.

Carbon fiber reinforced polymer (CFRP) composites are prone to developing localized material loss defects during long-term service, which can severely degrade their mechanical properties and structural reliability. To address this issue, this study proposes a multi-sensor synchronous monitoring method combining embedded fiber Bragg grating (FBG) sensors and surface-mounted electrical resistance strain gauges. First, finite element simulations based on the three-dimensional Hashin damage criterion were performed to simulate the damage initiation and propagation processes in CFRP laminates, revealing the complete damage evolution mechanism from initial defect formation to progressive failure. The simulations were also used to determine the optimal sensor placement strategy. Subsequently, tensile test specimens with prefabricated defects were prepared in accordance with ASTM D3039, and multi-sensor monitoring techniques were employed to capture multi-parameter, dynamic data throughout the damage evolution process. The experimental results indicate that embedded FBG sensors and surface-mounted strain gauges can effectively monitor localized material loss defects within composite laminate structures. Strain gauge measurements showed uniform strain distribution at all measuring points in intact specimens (with deviations less than 5%). In contrast, in defective specimens, strain values at measurement points near the notch edge were significantly higher than those in regions farther from the notch, indicating that the prefabricated defect disrupted fiber continuity and induced stress redistribution. The combined use of surface-mounted strain gauges and embedded FBG sensors was demonstrated to accurately and reliably track the damage evolution behavior of defective CFRP laminates.