This thesis work was conducted in the Department of Mechanical Engineering at the Cape Peninsula University of Technology (CPUT) and was submitted towards the partial fulfilment of the Masters Degree in Technology: Mechanical Engineering. / Recent years have witnessed a tremendous growth and significant advances in “smart” composites and “smart” composite structures. These smart composites integrate active elements such as sensors and actuators into a host structure to create improved or new functionalities through a clever choice of the active elements and/or a proper design of the structure. Such composites are able to sense a change in the environment and make a useful response by using an external feedback control system. Depending on their applications, smart composites usually make use of either the joint properties of the structure or the properties of the individual elements within the composites. The accumulation in the understanding of materials science and the rapid developments in computational capabilities have provided an even wider framework for the implementation of multi-functionality in composites and make “smart” composites “intelligent”.

Les structures composites intégrant des transducteurs piézoélectriques au cœur de la matière sont utilisées pour leur capacité à modifier leurs propriétés mécaniques en fonction de l’environnement, à contrôler leur intégrité structurale et à interagir avec l’homme ou avec d’autres structures.Ce travail se concentre sur les phases de conception préliminaire des structures composites intelligentes. Ces phases ne représentent que 5% du coût total d’un projet, mais conditionnent 80% du coût final du produit. Les principaux problèmes rencontrés lors de ces phases de conception préliminaire portent sur la détermination des propriétés matériau des transducteurs piézoélectriques et des matériaux composites utilisés, de l'influence de l'emplacement des transducteurs dans la structure ainsi que de l’influence du processus de fabrication, de la température et des endommagements sur le comportement final des structures composites intelligentes.Dans le processus de fabrication développé à l’Université de Technologies Belfort-Montbéliard (UTBM), l’élément-clé est un produit semi-fini appelé “soft layer”. Cette couche permet d’intégrer le réseau de transducteurs piézoélectriques au cœur de la structure composite. Le processus de fabrication de la “soft layer” ainsi que celui des structures intelligentes sont abordés dans cette thèse.Afin de trouver des solutions aux problèmes décrits ci-dessus, deux méthodes de caractérisation de composites intelligents ou adaptatifs sont présentées et utilisées : la méthode dite Resonalyser et la méthode du temps de vol. Après des études expérimentales et une comparaison des résultats obtenus, la méthode du temps de vol a été choisie comme méthode principale en raison de son faible coût de mise en œuvre et du fait qu’il s’agit d’une méthode de caractérisation in-situ. De plus, une nouvelle méthode appelée méthode CMB, basée sur la méthode du temps de vol a été développée afin de pouvoir facilement et rapidement extraire les constantes élastiques, en particulier le coefficient de Poisson.Des analyses expérimentales de sensibilité appliquées aux composites adaptatifs ont été effectuées.Premièrement, l’étude de l’influence de l’emplacement des transducteurs démontre qu’il est nécessaire de tenir compte de la position de la “soft layer” dans la modélisation du comportement de produit final. La position de cette couche dans l’épaisseur du produit a une influence notable sur les fréquences propres ainsi que les amplitudes modales de la structure. Cependant, l’ajout de la “soft layer” n’accroît pas le taux d’amortissement de la structure finale; et sa position dans l’épaisseur n’a aucune influence sur ce taux d’amortissement. La propagation des ondes de Lamb à l’intérieur du composite n’est pas impactée par le “soft layer”.Deuxièmement, l’étude de l’impact du processus de la fabrication nous renseigne sur l’influence notable des divers paramètres de réglage du processus de fabrication sur le comportement final de la structure composite intelligente.Troisièmement, l’étude de l’influence de la température sur des structures constituées de différents matériaux composites montre que le module de Young du produit final décroît quand la température augmente. Mais la diminution du module de Young en fonction de la température est différente selon les et les types de matériaux et les directions des fibres, en particulier pour les structures composites unidirectionnelles. De plus, cette étude montre également la sensibilité de la méthode du temps de vol vis-à-vis de la température. Ce dernier point est par ailleurs consolidé par la comparaison avec des résultats obtenus par une méthode de caractérisation ex-situ standard : l'analyse dynamique de la mécanique (DMA).Enfin, l'étude de l'impact des dommages mécaniques fournit une assez bonne référence pour les recherches futures. De cette façon, il est clair qu’une méthode de temps de vol peut être utilisée dans la surveillance de la santé structurale. / The composite structures embedding piezoelectric implants are developed due to their abilities of modifying mechanical properties according to the environment, of keeping their integrity, of interacting with human beings or with other structures.This study is focused on the preliminary design stages of smart composite structures, which represent only 5% of the total costs of a project, whereas 80% of the life cycle cost are set during the preliminary study phases. The top few problems during the preliminary design of smart composite structures are addressed in this work such as the determination of the material properties of the piezoelectric transducers and composite material used, the influence of transducers location, manufacturing process, temperature and damage on the behavior of the smart composite structures.Due to the manufacturing process developed at the Université de Technologie de Belfort-Montbéliard (UTBM), the most important element is a semi-finished product called “soft layer”. This special layer is used to embed the transducers system into the composite structures. The manufacturing process of “soft layer” as well as the smart composite structures are compiled in this report.In order to solve the problems described above, two characterization methods of composite material (Resonalyser method and Time-of-Flight method (T-o-F method)), are introduced and discussed. After experimental studies and comparing the results of these two methods, the T-o-F method is chosen as the main method for the following studies due to the fact that it is a low-cost and in-situ characterization method. Furthermore, a new method based on the T-o-F method is developed to easily and quickly extract the elastic constants, in particular the Poisson’s ratio.Experimental sensitivity analyses applied to the smart composite structures are performed with respect to the problems describes above. First of all, the study of the influence of transducers location demonstrates that the "soft layer” cannot be neglected to model the behavior of the final product. In particular, the through-the-thickness position has an influence on the eigenfrequencies and the modal amplitudes. However, the "soft layer” does not increase the overall damping ratio of the final structures and the through-the-thickness position of the "soft layer” has no influence on the damping ratios. The Lamb wave propagation inside the composite material is not impacted by the "soft layer”. Secondly, the study of the impact of manufacturing process demonstrates that the impact of variability of parameters due to the manufacturing process is very important on the final response of the structure. Thirdly, the study of the influence of temperature on different kinds of smart composite structures proves that when temperature increases, the Young’s modulus of the smart composites decreases. But the attenuation of Young’s modulus according to temperature is different along different fiber directions, especially for the unidirectional composite structures. Furthermore, in this study, the sensitivity of Time-of-Flight method with respect to temperature is well proved by comparing the results with a traditional method like Dynamic-Mechanical Analysis (DMA). Last but not least, the study of the impact of the mechanical damage gives a quite good reference for the future investigations. Along this way, it is possible to use a Time-of-Flight method in Structural Health Monitoring. In addition, some smart composite structures manufactured by the research team are given and their potential applications are discussed.

Recent developments show the applications of smart structure in different engineering fields. Smart structures can be used for shape and vibration control, structural health monitoring etc. Smart materials can be integrated to composite structure to enhance its abilities. Fiber reinforced composites are the advanced materials of choice in aerospace applications due to its high strength and stiffness, light weight and ability to tailor according to the design requirements. Due to complex manufacturing process and varying operating conditions, composites are susceptible to variation in material properties and damages. The present study focuses on the effect of uncertainties in material properties and damages on a smart composite structure. A cantilevered composite plate with surface mounted piezoelectric sensor/ actuator is considered in this study. The sensors and the actuators are connected through a conventional feedback controller and the controller is configured for vibration control application. Matrix cracks are considered as damage in the composite plate. To study the effect of material uncertainty, probabilistic analysis is performed considering composite material properties and piezoelectric coefficients as independent Gaussian random variables. Numerical results show that there is substantial change in dynamic response of the smart composite plate due to material uncertainties and damage. Deviation due to material uncertainty and damage can be compensated by actively tuning the feedback control system. Feedback control parameters can be properly adjusted to match the baseline response. Here baseline case represents the response of the undamaged smart composite plate with deterministic material properties. The change in feedback control parameters are identified as damage indicator. Feedback control based damage detection method is proposed for structural health monitoring in smart composite structure and robustness of the method is studied considering material uncertainties. Fractal dimension based damage detection method is proposed to detect localized matrix cracks in a composite plate with spatially varying material properties. Variation in material properties follows a two dimensional homogeneous Gaussian random field. Fractal dimension is used to extract the damage information from the static response of composite plate with localized matrix cracks. It is found that fractal dimension based approach is capable of detecting the location of the single and multiple damages from the static deflection curve. Robustness of the fractal dimension based damage detection method is studied considering spatial uncertainties in material properties.