Multi-layered sensor yarns for in situ monitoring of textile reinforced composites

In this contribution, the characteristic of yarns that have intrinsically conductivity as well as such with coaxial conductive coatings acting as in situ strain sensors are described. The objective of the based research projects is the real-time in situ sensing of both global stresses acting on fibre reinforced plastic (FRP) components and the detection of resulted local microscopic damages due to creep, delamination and micro-cracks in the fibre-matrix interphase of glass fibre (GFRP) and carbon fibre (CFRP) composites. Sensor materials similar to the particular FRP and its mechanical behaviour have been chosen. In the first approach, GF- and aramid-based sensor yarns have been developed with multiple tailored silver layer coating system capable to distinguish multiple scaled damage mechanism due to these effects globally and locally. The second approach bases on the piezoresistive effect of CF rovings for their usage as in situ strain sensors. In the next step, suitable fibre and polymer film-based cleading have been tested and evaluated, granting sufficient electrical isolation to avoid short-circuits between the conductive sensor layers itself or between the sensor and intrinsically conductive CFRP respectively. Initially, the sensor performance of global strain measurement, means the accumulated strain along the integration length of the sensor yarn, has been evaluated during tensile stressing of FRP with integrated suchlike functionalised sensor yarns.