An effective approach for an embedded piezo diagnostic layer into thick composite material is presented. The effectiveness of the approach is assessed in comparison to the surface-mounted layer. The proposed manufacturing alleviates difficulties associated with trimming edges of composites when embedding wires. The Electro-Mechanical Impedance technique is used to access the integrity of the piezoelectric sensors bonding process. Comparisons of ultrasonic guided waves are made between embedded and surface-mounted diagnostic layers and their penetration through and across the thickness of the composites. Temperature influences with the range from −40 °C up to 80 °C on embedded and surface-mounted guided waves are investigated. An investigation is carried out into the relationship between amplitude and time-of-flight with temperature at different excitation frequencies. The temperature has significant but different effects on amplitude and phase-shift of guided waves for the embedded layer compared to the surface-mounted layer. A Laser Doppler Vibrometer is used to identify the blue tack and impact damage. Both embedded and surface-mounted layers are shown to be an effective means of generating detectable wave scatter from damage.

A novel multifunctional diagnostic sensor is developed as a cost-effective, in-service structural health monitoring system for determining the initial quality of curing of a bonded composite repair patch and assessing its long-term durability on composite structure. The proposed multi-functional sensor technology involves the creation of a ‘tailor-to-order’ 2D conductive patterns onto step-sanded repair surface of composite repair patch using inkjet printing. In employing this methodology, bondline quality during curing and in service was successfully assessed via impedance spectroscopy and resistance change measurements, respectively. The ability of this technology to effectively monitor the integrity of the bondline and the extent of damage in real-time was investigated by subjecting the scarf-repaired carbon fiber reinforced polymer panels to 3-point bending fatigue and low-velocity impact tests. The obtained results were compared with those of transient infrared thermography and ultrasound inspection techniques, thus validating the proposed method.

Microcapsule-based carbon fiber reinforced composites were manufactured by wet layup, in order to assess their mechanical properties and determine their healing efficiency. Microcapsules at 10%wt. containing bisphenol-A epoxy, encapsulated in a urea formaldehyde (UF) shell, were employed with Scandium (III) Triflate (Sc (OTf)3) as the catalyst. The investigation was deployed with two main directions. The first monitored changes to the mechanical performance due to the presence of the healing agent within the composite. More precisely, a minor decrease in interlaminar fracture toughness (G_IIC) (−14%), flexural strength (−12%) and modulus (−4%) compared to the reference material was reported. The second direction evaluated the healing efficiency. The experimental results showed significant recovery in fracture toughness up to 84% after the healing process, while flexural strength and modulus healing rates reached up to 14% and 23%, respectively. The Acoustic Emission technique was used to support the experimental results by the onsite monitoring.

So far, there is no validated technology for characterizing the dispersion and morphology state of carbon nanotubes (CNTs) aqueous dispersions during sonication. Taking advantage of the conductive nature of CNTs, the main hypothesis of the current study is that Electrochemical Impedance Spectroscopy (EIS) is an appropriate technique for the in-situ monitoring and qualification of the dispersion state of CNTs in aqueous media. To confirm our hypothesis, we monitored the Impedance |Z| during the sonication process as a function of type CNTs/admixtures used for the preparation of the aqueous solutions and of crucial process parameters, such as the applied sonication power and duration (i.e., sonication energy). For dispersions above the percolation threshold, a drop of |Z| by approximately seven orders of magnitude was observed, followed by a linear reduction. The dramatic change in |Z| is regarded as an indication of the formation of a conductive path or destruction of an existing one during sonication and can be used to characterize the dispersion and morphology state of CNTs. The results of the EIS provide, straightforwardly and reliably, the required information to create an optimum dispersion protocol for conductive CNT suspensions. The produced dispersions are part of research focusing on the manufacturing of cement-based composite materials with advanced thermoelectric functionalities for energy harvesting. Such dispersions are not only limited to energy harvesting applications but also to applications where functionalities are introduced through the use of conductive-based suspensions.