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Temperature-dependent calibration and temperature compensation of elastic shape-memory alloy strain sensors for fiber-reinforced composite applications

  • Thomas Mäder received the Dipl.-Ing. degree in mechanical engineering, in 2007 and the Dr.-Ing. degree in mechanical engineering, in 2014, both from the Technische Universität Chemnitz, Chemnitz, Germany. From 2007 to 2013, he was a Research Assistant with the Institute of Materials Science and Engineering, Chemnitz, Germany. His research interest includes strain sensing and structural health monitoring of composite materials, carbon fibers, coating of materials, shape-memory alloy materials and the development of strain sensors for elastic materials.

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    Björn Senf is a research assistant at the Fraunhofer IWU since 2011. He received his joint master’s degree in computer aided engineering and analysis at the University of Applied Sciences in Leipzig, Germany and the UWS in Scotland. His research interest includes smart materials, especially shape memory alloys, as sensors and actuators. His focus is on the use of novel strain sensors for lightweight construction applications, the sensor and test bench design and the implementation of measurement applications for industrial applications.

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    Martin Zoch received the B.S. degree in mechanical engineering at the University of Applied Sciences in Mannheim, Germany, in 2014. He is currently pursuing the B.S. degree in civil engineering at Technische Universität Dresden, Dresden, Germany. Since 2017, he has been a student assistant with Fraunhofer Institute for Machine Tools and Forming Technology IWU, Dresden, 01187 Germany. His research interest includes the development of strain sensors.

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    Welf-Guntram Drossel was born in Freiberg, Germany in 1967. In 2014 he became a Full Professor in Adaptronics and Functional Lightweight Design. Since October 2012 he is Director of the Fraunhofer Institute for Machine Tools and Forming Technology concentrating his research on active materials, adaptronic components, technologies for functional integration as well as Additive Manufacturing. Prof. Drossel is an Associate Member of the International Academy for Production Engineering (CIRP) and Board Member of the European Research Association for Sheet Metal Working.
Published/Copyright: March 11, 2024
tm - Technisches Messen
From the journal tm - Technisches Messen Volume 91 Issue 3-4

Abstract

Strain sensors for fiber-reinforced plastics require higher elasticity and fatigue resistance than conventional strain gauges. Elastic strain sensors made of shape-memory alloys (SMA) meet this requirement. Due to greater elasticity, other procedures are required for their calibration than those recommended in standards. This paper presents a calibration method for shape-memory strain sensors as a function of ambient temperature and methods for temperature compensation are investigated. SMA strain sensors are manufactured as sensor patches from wire and layers of glass fiber fleece infiltrated with epoxy resin. The patches are bonded to bending specimens made of glass-fiber plastic composites. The calibration of the SMA sensors is implemented by means of a 4-point bending test using a self-built test stand. This is designed for operation in a climate chamber. The results show successful proof of feasibility of temperature compensation. The variation of the sensor signal in the unloaded state in the temperature response is less than 0.4 mV/V. The gauge factor depends on the temperature and is compensated by means of a regression with temperature sensor data. In combination with a temperature sensor, an almost complete compensation of the temperature-dependent behaviour is possible. A procedure is realised for calibrating SMA sensors at larger strains.

Zusammenfassung

Dehnungssensoren für faserverstärkte Kunststoffe erfordern eine höhere Elastizität und Ermüdungsfestigkeit als herkömmliche Dehnungsmessstreifen. Elastische Dehnungssensoren aus Formgedächtnislegierungen (FGL) erfüllen diese Anforderung. Aufgrund der höheren Elastizität sind für ihre Kalibrierung andere Verfahren erforderlich als die in Richtlinien empfohlenen. In diesem Beitrag wird ein Kalibrierverfahren für Formgedächtnis-Dehnungssensoren in Abhängigkeit von der Umgebungstemperatur vorgestellt und es werden Methoden zur Temperaturkompensation untersucht. FGL-Dehnungssensoren werden als Sensorpatches aus Draht und mit Epoxidharz infiltrierten Schichten aus Glasfaservlies hergestellt. Die Patches werden auf Biegeproben aus Glasfaser-Kunststoff-Verbunden aufgeklebt. Die Kalibrierung der FGL-Sensoren erfolgt durch einen 4-Punkt-Biegeversuch mit Hilfe eines selbstgebauten Prüfstandes. Dieser ist für den Betrieb in einer Klimakammer ausgelegt. Die Ergebnisse zeigen den erfolgreichen Nachweis der Machbarkeit der Temperaturkompensation. Die Schwankung des Sensorsignals im unbelasteten Zustand im Temperaturgang beträgt weniger als 0,4 mV/V. Der k-Faktor ist temperaturabhängig und wird durch eine Regression mit Temperatursensordaten kompensiert. In Kombination mit einem Temperatursensor ist die vollständige Kompensation des temperaturabhängigen Verhaltens möglich. Ein Verfahren zur Kalibrierung von FGL-Sensoren bei größeren Dehnungen ist realisiert.

Keywords: shape-memory alloy; strain sensors; calibration; temperature compensation; 4-point-bending test; fiber-reinforced plastic
Schlüsselwörter: Formgedächtnislegierung; Dehnungssensoren; Kalibrierung; Temperaturkompensation; 4-Punk-Biegeversuch; Faserkunststoffverbunde
Corresponding author: Thomas Mäder, Formgedächtnislegierungen, Fraunhofer IWU, Reichenhainer Straße 88, Chemnitz, Saxony, 09126, Germany, E-mail:

About the authors

Thomas Mäder

Thomas Mäder received the Dipl.-Ing. degree in mechanical engineering, in 2007 and the Dr.-Ing. degree in mechanical engineering, in 2014, both from the Technische Universität Chemnitz, Chemnitz, Germany. From 2007 to 2013, he was a Research Assistant with the Institute of Materials Science and Engineering, Chemnitz, Germany. His research interest includes strain sensing and structural health monitoring of composite materials, carbon fibers, coating of materials, shape-memory alloy materials and the development of strain sensors for elastic materials.

Björn Senf

Björn Senf is a research assistant at the Fraunhofer IWU since 2011. He received his joint master’s degree in computer aided engineering and analysis at the University of Applied Sciences in Leipzig, Germany and the UWS in Scotland. His research interest includes smart materials, especially shape memory alloys, as sensors and actuators. His focus is on the use of novel strain sensors for lightweight construction applications, the sensor and test bench design and the implementation of measurement applications for industrial applications.

Martin Zoch

Martin Zoch received the B.S. degree in mechanical engineering at the University of Applied Sciences in Mannheim, Germany, in 2014. He is currently pursuing the B.S. degree in civil engineering at Technische Universität Dresden, Dresden, Germany. Since 2017, he has been a student assistant with Fraunhofer Institute for Machine Tools and Forming Technology IWU, Dresden, 01187 Germany. His research interest includes the development of strain sensors.

Welf-Guntram Drossel

Welf-Guntram Drossel was born in Freiberg, Germany in 1967. In 2014 he became a Full Professor in Adaptronics and Functional Lightweight Design. Since October 2012 he is Director of the Fraunhofer Institute for Machine Tools and Forming Technology concentrating his research on active materials, adaptronic components, technologies for functional integration as well as Additive Manufacturing. Prof. Drossel is an Associate Member of the International Academy for Production Engineering (CIRP) and Board Member of the European Research Association for Sheet Metal Working.

Acknowledgments

The authors thank the German Federal Ministry of Education and Research for funding the collaborative research project FGLSensOPro, which allowed carrying out all works for this contribution. Many thanks go to Theo Wember from Cornerstone for his helpful support with the model creation of the regression analysis.

  1. Research ethics: Not applicable.

  2. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Competing interests: The authors state no conflict of interest.

  4. Research funding: Paper works were supported by German Federal Ministry of Education and Research via Projektträger Jülich under the grant number 03ZZ1046D.

  5. Data availability: The raw data can be obtained on request from the corresponding author.

References

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Received: 2023-10-16
Accepted: 2024-02-27
Published Online: 2024-03-11
Published in Print: 2024-03-25

© 2024 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Editorial
  3. Editorial
  4. Research Articles
  5. Textile-based piezoelectric impact sensors for fibre-reinforced plastic composites
  6. Textile-based strain sensors for fiber-reinforced composites under tension, compression and bending
  7. Distributed fiber optic sensors for structural health monitoring of composite pressure vessels
  8. Temperature-dependent calibration and temperature compensation of elastic shape-memory alloy strain sensors for fiber-reinforced composite applications
  9. Gesture and force sensing based on dielectric elastomers for intelligent gloves in the digital production
  10. What kind of phonation causes the strongest vocal fold collision? – A hemi-larynx phonation contact pressure study
  11. Concept studies and application development of textile integrated dielectric elastomer sensors for smart shoe technologies
https://doi.org/10.1515/teme-2023-0149
Keywords for this article
shape-memory alloy; strain sensors; calibration; temperature compensation; 4-point-bending test; fiber-reinforced plastic

Articles in the same Issue

  1. Frontmatter
  2. Editorial
  3. Editorial
  4. Research Articles
  5. Textile-based piezoelectric impact sensors for fibre-reinforced plastic composites
  6. Textile-based strain sensors for fiber-reinforced composites under tension, compression and bending
  7. Distributed fiber optic sensors for structural health monitoring of composite pressure vessels
  8. Temperature-dependent calibration and temperature compensation of elastic shape-memory alloy strain sensors for fiber-reinforced composite applications
  9. Gesture and force sensing based on dielectric elastomers for intelligent gloves in the digital production
  10. What kind of phonation causes the strongest vocal fold collision? – A hemi-larynx phonation contact pressure study
  11. Concept studies and application development of textile integrated dielectric elastomer sensors for smart shoe technologies
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