A one-step integrated forming and curing process for smart thin-walled fiber metal laminate structures with self-sensing functions

This study proposes and analyzes a novel one-step integrated forming and curing (IFC) process for thin-walled fiber metal laminates (FMLs) structures embedded with fiber Bragg grating (FBG) sensors, and have achieved both high-performance properties and self-sensing functions in the formed structures. A prototype machine and testing setup have been developed to validate the process's feasibility by manufacturing high-performance FMLs flat and curvature parts with effective self-sensing capabilities for real-time manufacturing and in-service monitoring. Numerical models considering curing-induced deformation and heat transfer during manufacturing have also been developed to support the analysis and validation of the self-monitoring capabilities of the intelligent FMLs parts. The results reveal that with proper control of pressure (e.g., 0.6 MPa) and time during forming and curing, high tensile and impact performance of FMLs can be maintained with embedded FBG, with less than a 3 % loss. Additionally, the IFC process can effectively lead to an apparent reduction of springback deformation in the formed FMLs (more than 80 %). The validation of the self-sensing function during the manufacturing process has been achieved by comparing the strain monitoring results with finite element (FE) simulation results during curing, with a minimum discrepancy of 2.0 %. For the in-service self-sensing function, comparison between FE analysis and surface-fixed strain gauges during the compression instability test confirmed the efficacy of FBG sensors, with a minimum discrepancy of 4.3 %. The results show that the proposed novel IFC process enables the successful manufacture of smart thin-walled FMLs parts with high shape accuracy and mechanical properties in a single step and holds significant promise for manufacturing self-sensing smart structures in the aerospace and aviation industries.