Measurement and Decoupling of Hygrothermal-Mechanical Effects with Optical Fibers: Development of a New Fiber BraggGrating Sensor

Composite materials are increasingly used in the aviation industry for various aircraft components due to their lightweight and mechanical performances. However, these materials are susceptible to degradation due to environmental factors such as hot–wet environments and freeze–thaw cycles, which can compromise their performance and safety over time. This study develops an innovative Fiber Bragg Grating (FBG) sensor system capable of not only measuring but also decoupling the simultaneous effects of temperature, humidity and strain. Unlike existing FBG systems, our approach integrates a novel theoretical framework and sensor configuration that accurately isolates these parameters in an epoxy resin material. The system incorporates three FBG sensors: one for temperature, one for temperature and humidity and a third one for all three factors. A theoretical framework based on linear strain superposition and constitutive laws was developed to isolate the individual contributions of each factor. Experimental validation in controlled hygrothermal conditions demonstrated the system’s ability to accurately detect and decouple these effects, enabling the monitoring of moisture absorption and composite degradation over time. The proposed system provides a reliable, lightweight and efficient solution for the long-term monitoring of composite structures in extreme conditions. Additionally, it enhances predictive maintenance by improving the accuracy of Health and Usage Monitoring Systems (HUMSs) and provides a method to correct data inconsistencies in already installed sensors, further extending their operational value.