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Abstract
Cost-effective and reliable damage detection is critical for the utilization of composite materials. This paper presents part of an experi-
mental and analytical survey of candidate methods for the in situ detection of damage in composite materials. The experimental results are
presented for the application of modal analysis techniques applied to graphite/epoxy specimens containing representative damage modes.
Changes in natural frequencies and modes were found using a laser vibrometer, and 2-D ®nite element models were created for comparison
with the experimental results. The models accurately predicted the response of the specimens at low frequencies, but coalescence of higher
frequency modes makes mode-dependant damage detection dif®cult for structural applications. The frequency response method was found to
be reliable for detecting even small amounts of damage in a simple composite structure, however the potentially important information about
damage type, size, location and orientation were lost using this method since several combinations of these variables can yield identical
response signatures. q 2002 Elsevier Science Ltd. All rights reserved.
Keywords: A. Polymer±matrix composites; B. Vibration; C. Finite element analysis; D. Non-destructive testing
detection in composites need to be developed to ensure that particular modes up to 1 kHz using the Galerkin method
the total cost of ownership of critical structures does not on cantilevered aluminum beams with notches, and a similar
become a limiting factor for their use. experiment was performed by Mitchell et al. [24] to detect
changes in the ®rst mode of a specimen wirelessly. Damage
1.2. Survey of modal evaluation techniques detection in more complicated geometries was investigated
by Purekar and Pines [25], who used this technique to search
Several techniques were researched for detecting damage for delamination in composite rotorcraft ¯exbeams. Again,
in composite materials, many of them focusing on modal ®nite element models were built to help to locate the sources
response [5±21]. These methods are among the earliest and of experimental changes in the transfer functions of their
most common, principally because they are simple to imple- specimens.
ment on any size structure. Structures can be excited by Zhang et al. [26] investigated the use of transmittance
ambient energy, an external shaker or embedded actuators, functions for health monitoring, a technique which does
and embedded strain gauges, piezos or accelerometers can not require the use of analytical models. A system of
be used to monitor the structural dynamic responses. piezo patches are placed on a structure, where some are
Changes in normal vibrational modes can be correlated to used as sensors and others as actuators and responses at
loss of stiffness in a structure, and usually analytical models certain sensor locations due to broadband actuation are
or experimentally determined response-history tables are recorded for the healthy structure to be later compared to
used to predict the corresponding location of damage [22]. a potentially damaged structure. Changes in curvature were
The dif®culty, however, comes in the interpretation of the used in this case to detect, locate and assess damage to the
data collected by this type of system. There are also detec- structure. One signi®cant ®nding was that the optimal range
tion limitations imposed by the resolution and range of the to actuate their structure was between 10 and 20 kHz,
individual sensors chosen, and the density with which they however they found that only frequencies less than 5 kHz
are distributed over the structure. There were many different (200±1800 Hz in most cases) were practical to collect
approaches described in the literature that use modal evalua- experimental data. Lastly, Valdes and Soutis [27] detected
tion techniques to locate damage in everything from small delamination in composite laminates using piezoceramic
specimens to full components. patches and piezoelectric ®lm sensors, again without the
One of the most thorough reports can be found in a use of models. Frequency sweeps between 8 and 14 kHz
recently published paper by Zou et al. [22], which presents were used to induce vibrations on the structure, and clear
a review of vibration-based techniques that rely on models reductions in modal frequencies were found as the delami-
for identi®cation of delamination in composite structures. nation area in the test specimen was increased.
The authors suggest that model-dependent methods are This present paper speci®cally investigates the feasibility
capable of providing both global and local damage informa- of modal evaluation techniques in detecting damage for
tion, as well as being cost-effective and easily operated. All health monitoring of composite structures. Characteristics
of the methods they assessed use piezo sensor and actuators examined include these methods' ability to detect various
along with ®nite element analysis results to locate and esti- types of damage, their precision in determining the damage
mate damage events by comparing changes in dynamic location, and their sensitivity to sensor density. The impact
responses. The paper compares the merits of four different of conformability for system implementation is also
dynamic response parameters: modal analysis, frequency assessed. A similar procedure is followed by several of
domain, time domain and impedance domain. The authors the papers presented earlier to evaluate these methods.
recommended modal analysis methods on account of their Composite laminated coupons were manufactured, and
global nature, low cost and ¯exibility to select measurement several representative forms of damage were introduced to
points, however they indicated that they lack the ability to these specimens. Experiments were performed to detect the
detect very small damage and require large data storage various forms of damage with different sensor systems.
capacity for comparisons. They claimed that frequency Finite element models were then created to validate these
domain methods alone were incapable of detecting the loca- results and to perform trade-studies. Finally a discussion is
tion of damage, however when combined with time domain presented remarking on the potential role of frequency
methods they can detect damage events both globally and response methods in a SHM system.
locally. Lastly, the impedance domain techniques were
described as suitable for detecting most delamination
reliably, unless the layers above the defect are very thin 2. Experimental setup
compared to the remaining laminate.
Several other papers have documented the use of a 2.1. Specimen manufacture
combination of the modal analysis and frequency domain
methods to detect various damage types with piezo actuators Four graphite/epoxy panels were manufactured according
and sensors coupled with ®nite element or analytical to standard in-house procedure [28] using AS4/3501-6. A
models. Banks and Emeric [23] investigated changes in [90/^45/0]s quasi-isotropic laminate was selected for these
S.S. Kessler et al. / Composites: Part B 33 (2002) 87±95 89
chirp signal. The laser was set to scan through a ®ne mesh of
points along each specimen's surface recording the velocity
response at that grid position. This data along with compli-
mentary data from a stationary control laser were used to
produce frequency/response plots and mode shapes.
4. Results
Table 1
Natural frequencies and mode shapes as determined from scanning laser vibrometer data
Fig. 7. Frequency response plot from vibrometer for all specimens range of Fig. 8. Frequency response transfer function plot from FEM in I-DEAS,
0±500 Hz. range 0±20 kHz.
92 S.S. Kessler et al. / Composites: Part B 33 (2002) 87±95
Fig. 9. First four mode shapes of control specimen plotted in I-DEAS post-
processor: (a) ®rst bending, (b) second bending, (c) ®rst torsion, (d) third
bending.
Fig. 10. Frequency response transfer function plot from I-DEAS, range of
along the free edge, and was modeled as described earlier.
0±500 Hz.
Several other similar plots were generated in I-DEASe
for the other damage mode models, all yielding similar
trends. The signi®cance of these plots will be delineated The delaminated specimens have a region that effectively
in Section 5. behaves as two separate laminates with reduced stiffness,
and the set with one edge delaminated has an even more
prominent change in the torsion modes due to its asym-
5. Discussion metry. The fatigue-damaged specimens are affected by
matrix cracking and ®ber-matrix debonding, and the four-
5.1. Effect of damage on frequency response point bending specimens contain broken ®bers, which also
reduce the modulus. Changes in the specimens with the
For both the numerical (FE) and experimental results it is drilled hole can be explained by the reduced stiffness and
evident that all the forms of damage investigated in this inertia.
study caused detectable changes in the natural frequencies As shown in the literature, a strong correlation can often
of a simple coupon. These changes are present in each of the be found between relative frequency reduction and the area
lower normal frequencies discovered, and become more damaged by a particular mechanism, however it is dif®cult
pronounced at higher frequencies to a degree that corre- to draw any conclusions about the criticality of the damage
sponding modes between the control and damaged speci- since there is no information regarding the form of the
mens become indiscernible. This frequency reduction can damage or its orientation. This limitation is illustrated by
be explained by classical structural dynamics [34]. Natural a delamination with an area of 50 £ 20 mm 2 that has a
frequencies are determined by the boundary conditions of a signi®cantly different effect on a structure depending on
system through the variable l 2, which is determined by the whether the longer delamination direction is oriented
characteristic equation of the structure, and is multiplied by parallel or perpendicular to the sensor. Delamination that
the ratio
EI=m0:5 ; where E is the modulus, I the second is more severe along the length of a specimen tends to cause
moment of area and m is the mass. When damage is intro- a larger reduction on the bending modes, while delamina-
duced to a specimen by one of a variety of mechanisms, the tion along the width appears to impact the torsional modes
resulting local loss of stiffness directly affects this ratio, more adversely. It is also important to note that the 5±10%
thereby affecting the natural frequencies of the structure. reduction in natural frequency caused by a 6.4 mm diameter
Table 2
Natural frequencies and mode shapes as determined from FEM in I-DEAS
through-hole yields almost identical transfer function results geometry model is the reason why most work in the litera-
to that of a 50 £ 50 mm 2 center delamination, however there ture has avoided model-dependant SHM solutions. Instead,
is a noteworthy difference in the signi®cance to the struc- they have tended towards time history change comparisons
ture. The only type of damage that was slightly distinguish- while using this technique. Without the use of models
able at low frequency ranges was fatigue damage, which however, the frequency response method is limited to low
produced many high-energy local modes that were not frequency ranges where the response peaks are still distinct.
present in any of the other specimens. Based on these A consequence of this limitation is that while the principal
results, it is likely that an observer can discern whether a global modes can be detected, the local modes of the struc-
structure has been damaged by observing its frequency ture, which hold the most detailed information about the
response, however it would be dif®cult to differentiate damage present, will not be detected. Even so, as will be
reliably between damage types, locations and orientations discussed in the following section, the frequency response
without capturing several accurate bending and torsional method can still play an important role in a SHM system,
modes and building a large database of damage simulations and preliminary models are useful in predicting the response
model and experimental data. of a structure to help design a successful sensor layout.
5.2. Comparison of tests to model 5.3. Role of frequency response methods in SHM
In comparing the test results to those solved in I-DEASe, There are many advantages of using a frequency response
a good correlation was found without tuning or adjusting the method in a SHM system; they can be implemented cheaply,
model. The models consistently yielded the correct pro- they can be light and conformal, and they can provide good
gression of mode shapes, and natural frequencies around insight as to the global condition of the system. The limita-
1±8% above those found in experiments, which could be tions are that they provide little information about the local
explained by a variety of factors. A small amount of error damage area unless large quantities of sensors are used
could be attributed to ®ber misalignment and resin ¯ow or along with accurate numerical models; and then it can be
bleed-out during curing that created slight differences in the argued that damage large enough to be detected globally
modulus, density and thickness of the laminate, affecting the may already be critical in many structures. Clearly this
natural frequencies by a factor of
Et2 =r0:5 ; which is a method does not suf®ce as the sole sensor set in a SHM
manipulated version of the previous constant where t is system, however that does not exclude them from having
the thickness and r is the density. The experimentally any role in the system. The most attractive implementation
obtained averages of these variables were identical to of the frequency response method is one performed
those entered into the model, however signi®cant variances passively for low frequencies using ambient vehicle vibra-
are associated with them, which would account for as much tions, caused by the engines or aerodynamic loads for
as a 4% deviation from the predicted solution. Another example. Comparing global transfer functions for
possible difference could have been introduced by the prescribed frequency ranges at selected positions could
actuating piezos, which add non-negligible mass to the provide a good foundation for a ®rst and last line of defense
specimens and may also have shifted the measurement in a SHM system. A passive method such as this could
equipment slightly out of phase due to the elasticity in the continuously monitor components of a structure without
thin adhesive layer between them and the composite requiring much processing power in order to direct more
laminate. The largest variable sensitivity in the system accurate and energy-intensive active sensor systems where
was found to be in the simulated clamped boundary condi- to query for a more detailed survey of potential damage.
tion. It was experimentally found that by slightly loosening Alternatively, widespread fatigue may be too small or
the clamp, the lowest natural frequencies in the control gradual to be detected by ®ne-tuned active methods, and
specimen could drop as much as 10%, which overshadowed may be better detected by an ambient frequency response
most forms of damage that was detected in these specimens. method by setting a global limit on allowable natural
This result was con®rmed by a ®nite element model, which frequency decay of the structure over time. To accomplish
replaced the completely clamped boundary condition with a this role in a SHM system, ®rst a model would have to be
pin on the 25 mm line and a clamp at the base of the speci- built which would be used to select an appropriate range of
men. This model yielded a 9% reduction in the ®rst several frequencies to clearly detect resonant frequencies and to test
resonant frequencies. Consequently, much care was taken to various placements for sensors. Modal reduction can be
produce a consistent clamping pressure with the torque accomplished using a variety of sensors such as strain
wrench for each of the experiments performed, however gauges, piezoelectric wafers or accelerometers, which
the inability to simulate an ideal clamp, as evident by an must be placed strategically throughout the structure.
observed slope at the clamp, most likely contributed to the Then a damaged model should be used to con®rm that
majority of the experimental error. realistic damage would be detected from the transfer func-
The strong dependence on accurate boundary conditions tion for the selected frequency range. Lastly these results
to retrieve accurate frequency responses for even a simple should be experimentally veri®ed on a representative
94 S.S. Kessler et al. / Composites: Part B 33 (2002) 87±95
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