An intelligent CFRP bolt with embedded carbon nanotube eddy current sensors for damage self‐diagnosis of bolted composite joints

Abstract

AbstractRecognizing the critical demand for composite bolts and the damage‐mode complexity of composite bolt joints, this study introduces the concept of an intelligent carbon fiber reinforced polymer (CFRP) bolt, which achieves self‐monitoring of damage in small and complex CFRP bolted joints. The proposed eddy current sensor (ECS) is mainly composed of a coil made of carbon nanotube film and encapsulated with epoxy resin film. This achieves homogeneous embedding of the sensor by using the same material for both sensor and bolt. The CFRP bolt is fabricated by molding process, with the proposed ECS embedded in bolt shank. The numerical simulation results indicate that hole‐edge damages impact the distribution of induced current density and eddy current flow in CFRP plates. Additionally, the impedance amplitude of the ECS effectively monitors bearing damage propagation. Shear tests confirm that the integration method of the proposed ECS within the CFRP bolt introduces negligible intrusion to the host bolt's integrity. Experimental results demonstrate that the intelligent CFRP bolt can effectively monitor the damage propagation at the hole edge, with an accuracy for bearing damage exceeding 0.5 mm. At a working frequency of 10 MHz, the sensor's sensitivity in detecting a 0.5 mm bearing damage reaches 4.20%.Highlights An intelligent CFRP bolt was fabricated using the molding method. The embedding of the ECS did not cause adverse effects on the bolt. The proposed EC sensor is composed of carbon nanotube and epoxy resin adhesive films. The eddy current distribution at the hole edge of the CFRP bolted joints is analyzed. The ability of intelligent bolts to monitor hole edge damage is verified by experiments.