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By combining the two types of magnetoelastic and magnetochromatic materials in an epoxy, we can make a hybrid system that exhibits an optical response due to an elastic strain. It could be used in structural health monitoring, for real-time monitoring of crack propagation or general evaluation of the condition of a structure, both visualized by a change in color. In this study, magnetostrictive polymer composites (MPCs) with Fe81Al19 (Alfenol) alloy particles are evaluated to determine magneto-elastic properties in composite patches attached to a surface, prior to understanding the full hybrid magneto–elasto–optical interactions. To measure static magneto-elastic performance, a tension apparatus within a solenoid was fabricated to apply uniform strain to the MPC patch on an aluminum dog-bone substrate. It was demonstrated that, for epoxies with an elastic modulus higher than ~0.1 GPa, a tensile strain/stress applied to the composite improved magneto-elastic coupling, resulting in increased permeability values, at least up to strains of 0.1%. Composites were fabricated with both spherical and flake-shaped powders, with flake-shaped powders exhibiting better magnetic responses than those with spherical morphology. Alfenol MPCs were also measured dynamically at ultrasonic frequencies, exhibiting comparable dynamic sensing performance to Galfenol at 120 kHz using ultrasonic guided wave techniques.

Static and Dynamic Magneto-Elastic Sensing Properties of Fe-Al Alloy Powder-Epoxy Composite Patches