Real-time self-monitoring properties in 3D printed continuous carbon fiber reinforced thin-walled composite structures under large deformation

Huang, Y. and Wang, D. and Wen, W. and Zhu, W. and Li, J. and Cheng, P. and Peng, Y. and Yu, T. and Wang, K. and Ahzi, S. (2025) Real-time self-monitoring properties in 3D printed continuous carbon fiber reinforced thin-walled composite structures under large deformation. Composite Structures, 369: 119341. ISSN 0263-8223

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Abstract

Deformation monitoring is a crucial approach to ensuring safety and reliability of thin-walled structures. In this study, an electrical-resistance-based deformation monitoring method was utilized for real-time structural health monitoring of 3D printed continuous carbon fiber reinforced thin-walled composite structures. The correlation between deformation and electrical resistance changes was investigated in quasi-static lateral and axial compression for the composite structures with three different layer heights. Results showed that the mechanical–electrical behaviors during lateral and axial compression processes manifested distinct forms. A bilinear relationship between relative resistance change and compression displacement during lateral compression was obtained. Furthermore, the composite structures with lower layer heights demonstrated a higher linear correlation coefficient. Under axial compression, the relative resistance change showed a fluctuating fall/rise pattern. This pattern was associated with intricate damage morphology observed in the composite structures, such as fiber-to-fiber contact, fiber breakage, and fiber pull-out. In addition, the relative resistance change demonstrated a falling-rising pattern in the composite structures with a layer height of 0.3 mm, while it exhibited a falling-rising-falling pattern with other layer heights. The established correlation between the relative resistance change and deformation could facilitate real-time self-monitoring of deformation and failure states in thin-walled structures.