Multifunctional composite structures with embedded conductive yarns for shock load monitoring and failure detection

This study evaluates the performance of composite structures with embedded conductive yarns during shock loads to create a multifunctional system for immediate failure detection. The scalable sensing yarns were made by braiding Kevlar fibers with Nitinol fibers and then integrating them into a carbon/epoxy prepreg. The multifunctional structure was subjected to a Mach 2 air blast load using a shock tube apparatus. The embedded sensor yarns were used to record their electrical performance, while Digital Image Correlation captured full-field displacements, velocities, and strains. In addition, pressure transducers measured shock event pressures. The results revealed that through-thickness failure of the laminated composite occurred at approximately 2.5% strain, which was visually observable. However, the embedded sensor exhibited out-of-range electrical measurements at around 1.5% strain, even though no visible structural damage was present. This demonstrates the embedded sensing yarns’ ability to detect delamination-type failures by responding to interlaminate damage, highlighting their advantages over conventional external sensors. Similarly, the gauge factor for the fiber system was determined to be 1.89 ± 0.07. This multifunctional system shows great potential for enhancing composite structure safety and performance in high-performance aerospace applications and offering real-time structural health assessment.