Surface-applied fibre optic strain sensors were investigated using a unique validation facility equipped with application-independent optical reference systems. First, different adhesives for the sensor's application were analysed regarding their material properties. Measurements resulting from conventional measurement techniques, such as thermo-mechanical analysis and dynamic mechanical analysis, were compared with measurements resulting from digital image correlation, which has the advantage of being a non-contact technique. Second, fibre optic strain sensors were applied to test specimens with the selected adhesives. Their strain-transfer mechanism was analysed in comparison with conventional strain gauges. Relative movements between the applied sensor and the test specimen were visualized easily using optical reference methods, digital image correlation and electronic speckle pattern interferometry. Conventional strain gauges showed limited opportunities for an objective strain-transfer analysis because they are also affected by application conditions.
Strain sensors embedded in or attached to structural components have to measure the real deformation of the structure over the whole period of use. The user must know how reliably installed sensors provide strain measurement results. For this purpose, test facilities or coupon tests are used. In order to characterize the strain transfer quality from the host structure into surface-applied strain sensors, a unique testing facility has been developed. This facility can be used both for fiber optic and resistance strain sensors. Originally developed for fiber Bragg grating based sensors, the KALFOS facility (=calibration of fiber optic sensors) uses Digital Image Correlation (DIC) and Electronic Speckle Pattern Interferometer (ESPI) as unbiased referencing methods. It is possible to determine experimentally the strain transfer mechanism under combined thermal and mechanical loading conditions. This experimental characterization method will reveal weaknesses in commonly used strain sensors, and the investigation of the material systems used for fiber optic and other strain sensors (particularly the coating/substrate - adhesive combination). The KALFOS facility allows matching of specific measurement requirements with environmental conditions.