The purpose of this study is to characterize the plasma spray deposits used for attaching intrinsic Fabry-Perot interferometric fiber optic strain sensors. The deposits must maintain adhesion at elevated temperatures without distorting the sensors' signals. Two different material systems were tested and modeled, a nickel based alloy and yttria-stabilized zirconia. The material properties of the deposits and the thermal stresses in the system were evaluated to determine attachment lifetime of the sensors. The encapsulated sensors' signals were collected before and after plasma spraying and at elevated temperatures. The material properties of the deposits were evaluated by electron microscopy, energy dispersive x-ray spectroscopy, scratch testing, thermal fatigue testing, and nanoindentation. The thermal stresses were evaluated by Raman spectroscopy and from finite element analysis in COMSOL® Multiphysics®. Several of the sensors broke during encapsulation due to the plasma spray processing conditions and the signals experienced distortion at elevated temperatures. The sensors can be treated to remove this interference to allow for this deposit attachment. The nickel based alloy's ductility and lamellar microstructure allowed for non catastrophic relaxation mechanisms to relieve induced thermal stresses. The yttria stabilized zirconia failed catastrophically at elevated temperatures due its lack of compliance to mismatches in thermal expansion. A high melting point metallic deposit, similar to the nickel based alloy, is desirable for fiber optic sensor attachment due to its ductility, thermal expansion, and dominant relaxation mechanisms. The processing conditions may need to be optimized to allow for the sensors' protection during encapsulation. / Master of Science

Coatings utilizing the piezospectroscopic (PS) effect of alpha alumina could enable on the fly stress sensing for structural health monitoring applications. While the PS effect has been historically utilized in several applications, here by distributing the photo-luminescent material in nanoparticle form within a matrix, a stress sensing coating is created. Parallel to developing PS coatings for stress sensing, the multi-scale mechanics associated with the observed PS response of nanocomposites and their coatings has been applied to give material property measurements, providing an understanding of particle reinforced composite behavior. Understanding the nanoparticle-coating-substrate mechanics is essential to interpreting the spectral shifts for stress sensing of structures. In the past, methods to experimentally measure the mechanics of these embedded nano inclusions have been limited, and much of the design of these composites depend on computational modeling and bulk response from mechanical testing. The PS properties of Chromium doped alumina allow for embedded inclusion mechanics to be revisited with unique experimental setups that probe the particles state of stress under applied load to the composite. These experimental investigations of particle mechanics will be compared to the Eshelby theory and its derivative theories in addition to the nanocomposite coating mechanics. This work discovers that simple nanoparticle load transfer theories are adequate for predicting PS properties in an intermediate volume fraction range. With fundamentals of PS nanocomposites established, the approach was applied to selected experiments to prove its validity. In general it was observed that the elastic modulus values calculated from the PS response were similar to that observed from macroscale strain measurements such as a strain gage. When simple damage models were applied to monitor the elastic modulus, it was observed that the rate of decay for the elastic modulus was much higher for the PS measurements than for the strain gage. A novel experiment including high resolution PS maps with secondary strain maps from digital image correlation is reviewed on an open hole tension, composite coupon. The two complementary measurements allow for a unique PS response for every location around the hole with a spatial resolution of 400 microns. Progression of intermediate damage mechanisms was observed before digital image correlation indicated them. Using the PS nanocomposite model, elastic modulus values were calculated. Introducing an elastic degradation model with some plastic deformation allows for estimation of material properties during the progression of failure. This work is part of a continuing effort to understand the mechanics of a stress sensing PS coating. The mechanics were then applied to various experimental data that provided elastic property calculations with high resolution. The significance is in the experimental capture of stress transfer in particulate composites. These findings pave the way for the development of high resolution stress-sensing coatings.