Fabrication and characterization of a metal-packaged regenerated fiber Bragg grating strain sensor for structural integrity monitoring of high-temperature components

Assessment of the structural integrity of components operating at high temperatures requires the development of novel sensors to measure strain. A metal-packaged regenerated fiber Bragg grating (RFBG) sensor is developed for measurement of strain using titanium–silver magnetron sputtering and nickel electroplating. The strain response of the sensor mounted onto a flat tensile specimen by spot welding is evaluated by uniaxial tensile tests at constant temperatures ranging from room temperature to 400 °C. Similar tests are performed on a bare RFBG sensor for comparison. The metal-packaged RFBG strain sensor exhibits higher strain sensitivity than that of the bare RFBG sensor, as well as good linearity, stability and repeatability of strain measurements. A three-dimensional finite element model of the sensor is established to predict the strain sensitivity based on the sensing principle of the fiber Bragg grating. Comparisons of the experimental results with the numerical predictions for the strain sensitivity show a satisfactory agreement. These results demonstrate that the metal-packaged RFBG strain sensors can be successfully fabricated by combining magnetron sputtering with electroplating, and provide great promise for structural integrity monitoring of high-temperature components.