Filament wound composites (FWC) consist of multiple layers of carbon/glass fibres within an epoxy matrix at different angles of orientation to achieve required mechanical properties. The type of hybrid composite and method of fabrication may be tailored to develop a smart pipe with embedded sensors for use in mineral exploration drill pipe applications. Experimental work and numerical simulations were performed in order to understand the effect of the filament angle-ply and how embedded sensors altered the overall mechanical structure strength of the angle-ply composite. Numerical analysis was performed using Hypersizer, to understand the stress distribution on each of the laminated layers, their angles, and the presence of a sensor on the strength of the composite’s structure. The experimental work was carried out to validate the numerical analysis results.
Experiments on two specimens are reported in this study, being with and without an embedded sensor. Eight plies were fabricated with the characteristic angle-ply of filament, wound in a rhomboid pattern. Due to the electrical conductivity of carbon fibre, the sensors’ performance was anticipated to deteriorate. Consequently a hybrid structure was designed. Glass fibre was wrapped around the sensors for isolation and the glass fibre, along with the sensors were then embedded in the carbon fibre filament wound structure. The fabricated hybrid specimens were then subjected to simple tensile tests in the lab. The mechanical strength of both specimens, with and without sensors, was compared to determine the effect of embedding the sensor within this hybrid composite.