Airborne Transducer Integrity under Operational Environment for Structural Health Monitoring

Durability Assessment of Bonded Piezoelectric Wafer Active Sensors for Aircraft Health Monitoring Applications

This study conducted experimental and numerical investigations on piezoelectric wafer active sensors (PWASs) bonded to an aluminum plate to assess the impact of bonding degradation on Lamb wave generation. Three surface-bonded PWASs were examined, including one intentionally bonded with a reduced adhesive to create a defective bond. Thermal cyclic aging was applied, monitoring through laser Doppler vibrometry (LDV) and static capacitance measurements. The PWAS with the initially defective bond exhibited the poorest performance over aging cycles, emphasizing the significance of the initial bond condition. As debonding progressed, modifications in electromechanical behavior were observed, leading to a reduction in wave amplitude and distortion of the generated wave field, challenging the validity of existing analytical modeling of wave-tuning curves for perfectly bonded PWASs. Both numerical simulations and experimental observations substantiated this finding. In conclusion, this study highlights the imperative of a high-integrity bond for the proper functioning of a guided wave-based structural health monitoring (SHM) system, emphasizing ongoing challenges in assessing SHM performance.

An Efficient Procedure for Bonding Piezoelectric Transducers to Thermoplastic Composite Structures for SHM Application and Its Durability in Aeronautical Environmental Conditions

Piezoceramic transducers (PCTs) bonded to carbon fiber-reinforced plastic (CFRP) composite structures must be durable as well as remain properly bonded to the structure in order to provide reliable data for accurate guided-wave-based structural health monitoring (SHM) of aeronautical components. The current method of bonding transducers to composite structures through epoxy adhesives faces some shortcomings, such as difficult reparability, lack of weldability, longer curing cycles, and shorter shelf life. To overcome these shortcomings, a new efficient procedure for bonding the transducers to thermoplastic (TP) composite structures was developed by utilizing TP adhesive films. Application-suitable TP films (TPFs) were identified and characterized through standard differential scanning calorimetry (DSC) and single lap shear (SLS) tests to study their melting behavior and bonding strength, respectively. Special PCTs called acousto-ultrasonic composite transducers (AUCTs) were bonded to high-performance TP composites (carbon fiber Poly-Ether-Ether-Ketone) coupons with a reference adhesive (Loctite EA 9695) and the selected TPFs. The integrity and durability of the bonded AUCTs in aeronautical operational environmental conditions (AOEC) were assessed in accordance to the standard Radio Technical Commission for Aeronautics DO-160. The AOEC tests performed were operating low and high temperatures, thermal cycling, hot-wet, and fluid susceptibility tests. The health and bonding quality of the AUCTs were evaluated by the electro-mechanical impedance (EMI) spectroscopy method and ultrasonic inspections. The AUCT defects were created artificially and their influence on the susceptance spectra (SS) was measured to compare them with the AOEC-tested AUCTs. The results show that a small change occurred in the SS characteristics of the bonded AUCTs in all of the adhesive cases after the AOEC tests. After comparing the changes in SS characteristics of simulated defects with that of the AOEC-tested AUCTs, the change is relatively smaller and therefore it can be concluded that no serious degradation of the AUCT or the adhesive layer has occurred. It was observed that the most critical tests among the AOEC tests are the fluid susceptibility tests, which can cause the biggest change in the SS characteristics. Comparing the performance of the AUCTs bonded with the reference adhesive and the selected TPFs in the AOEC tests, it was seen that some of the TPFs, e.g., Pontacol 22.100 outperforms the reference adhesive, while the other TPFs have similar performance to that of the reference adhesive. Therefore, in conclusion, the AUCTs bonded with the selected TPFs can withstand the operational and environmental conditions of an aircraft structure, and hence, the proposed procedure is easily installed, reparable, and a more reliable method of bonding sensors to aircraft structures.

Lead Zirconate Titanate Transducers Embedded in Composite Laminates: The Influence of the Integration Method on Ultrasound Transduction

In the context of an embedded structural health monitoring (SHM) system, two methods of transducer integration into the core of a laminate carbon fiber-reinforced polymer (CFRP) are tested: cut-out and between two plies. This study focuses on the effect of integration methods on Lamb wave generation. For this purpose, plates with an embedded lead zirconate titanate (PZT) transducer are cured in an autoclave. The embedded PZT insulation, integrity, and ability to generate Lamb waves are checked with electromechanical impedance, X-rays, and laser Doppler vibrometry (LDV) measurements. Lamb wave dispersion curves are computed by LDV using two-dimensional fast Fourier transform (Bi-FFT) to study the quasi-antisymmetric mode (qA0) excitability in generation with the embedded PZT in the frequency range of 30 to 200 kHz. The embedded PZT is able to generate Lamb waves, which validate the integration procedure. The first minimum frequency of the embedded PZT shifts to lower frequencies and its amplitude is reduced compared to a surface-mounted PZT.

Experiments and modelling of ultrasonic waves in composite plates under varying temperature

Guided wave (GW) structural health monitoring (SHM) systems offer an attractive solution as an in-situ quasi real-time assessment of structural damage, but their sensitivity and efficiency may be impaired under varied environmental and operational conditions. Thus, virtual tests, such as that based on the Finite Element (FE) method, represent a valid approach for simulating and investigating SHM systems, enabling a substantial reduction in experimental campaigns. In this work, GW propagation characteristics in a carbon fibre-reinforced composite plate are studied under a varying temperature condition, representative of the aeronautics application. At first, GW SHM system was physically tested at room temperature (20^°C), and the results were used to calibrate and assess the proposed FE modelling approaches, characterised by different element types and mesh sizes. A temperature independent averaged time compensation factor is proposed to mitigate the numerical data dependency on excitation frequency and propagation angle. Two temperature variations (from 20^°C to -50^°C, and 20^°C to 65^°C) were experimentally and numerically considered to investigate the effect of varying temperature on the GW. For all test cases, the compensated numerical data was compared to the experimental results, and discussed in terms of dispersion curves, focusing on the zero-order symmetric, S₀, and antisymmetric, A₀, modes. Results show that both 2D and 3D FE approaches can accurately predict the changes in GW due to varying temperature, with the group velocity of the A₀ mode being less sensitive to temperature variations.

Influence of Composite Thickness on Ultrasonic Guided Wave Propagation for Damage Detection

In this paper, the propagation properties of ultrasonic guided waves (UGWs) in different-thickness composites (i.e., 2, 4 and 9 mm) were critically assessed, and their effectiveness for damage detections and localisations under varying temperatures was demonstrated. A diagnostic film with phased-array lead zirconate titanate (PZT) transducers based on the ink-jet printing technique was used in the experiments. Initially, the dispersion curves for these composites were compared. Next, the effects of the composite thickness on the A₀ and S₀ mode amplitudes and the group velocity were investigated by active sensing. Next, the behaviours of UGWs under varying temperatures in different-thickness plates were also investigated. Finally, surface-mounted artificial damage and impact damage were detected and located in different composites.

Smart Patch for Structural Health Monitoring of Composite Repair

The bondline integrity of a repair patch to the parent composite laminate is considered the most important factor in the repair design. A smart repair patch is proposed here to allow for real-time ultrasonic guided wave monitoring of repaired composites. A diagnostic film with lead zirconate titanate (PZT) transducers and inkjet-printed wires is embedded into the repair patch using a cut-out method. The electro-mechanical impedance (EMI) method is used to verify the integrity of the embedded PZT transducers. The performance of the smart repair patch is assessed on the external panel with artificial bondline delamination and surface-mounted artificial damage. The damage index correlation coefficient and delay-and-sum (DAS) algorithm are used for damage detection and localization. The results show that the developed repair patch can successfully detect and locate damages.

Structural Health Monitoring Cost Estimation of a Piezosensorized Aircraft Fuselage

Guided waves-based SHM systems are of interest in the aeronautic sector due to their lightweight, long interrogation distances, and low power consumption. In this study, a bottom-up framework for the estimation of the initial investment cost (COTC) and the added weight (WAW) associated with the integration of a SHM system to an aircraft is presented. The framework provides a detailed breakdown of the activities and their costs for the sensorization of a structure using a fully wired approach or the adoption of the printed diagnostic film. Additionally, the framework considers the difference between configuring the system for Manual or Remote data acquisition. Based on the case study presented on the sensorization of a regional aircraft composite fuselage, there is a trade-off between COTC and WAW for the SHM options considered. The Wired–Manual case leads to the lowest COTC with the highest WAW, while the combination of diagnostic film with a Remote system leads to the highest COTC and the lowest WAW. These estimations capture the characteristics of each system and can be integrated into cost–benefit analyses for the final selection of a particular configuration.

The durability of flexible eddy current array (FECA) sensors in harsh service environments

Sensors for structural health monitoring (SHM) need to be permanently integrated on structures and withstand the harsh service environments, which has been a big challenge for the application of SHM in aircrafts. This paper focuses on the durability of flexible eddy current array (FECA) sensors in harsh service environments of aircrafts, including vibration environment and several typical exposed environments. First, a kind of FECA sensor is illustrated and its integration method is proposed. Moreover, in order to study the durability of the sensor in vibration environment, the modal analysis is performed by the finite element method. According to the simulation results, the durability experiment in vibration environment is carried out under the fourth order vibration mode, which makes the sensor suffer the harshest vibration loads. During the vibration experiment, output signals of the sensor keep stable and the sensor is well bonded to the structure, which shows the integrated sensor has high durability in vibration environment. Finally, the durability of integrated sensors is separately tested in three exposed environments, including salt fog corrosion environment, fluid immersion environment, as well as hygrothermal and ultraviolet-radiation environment. After these environmental exposure experiments, all sensors are well bonded to structures and can effectively monitor fatigue cracks, which shows great durability. Therefore, FECA sensors can survive in harsh service environments of aircrafts, which provides important support for the engineering applications of FECA sensors.

Design of a Large-Scale Piezoelectric Transducer Network Layer and Its Reliability Verification for Space Structures

As an effective structural health monitoring (SHM) technology, the piezoelectric transducer (PZT) and guided wave-based monitoring methods have attracted growing interest in the space field. When facing the large-scale monitoring requirements of space structures, a lot of PZTs are needed and may cause problems regarding to additional weight of connection cables, placement efficiency and performance consistency. The PZT layer is a promising solution against these problems. However, the current PZT layers still face challenges from large-scale lightweight monitoring and the lack of reliability assessment under extreme space service conditions. In this paper, a large-scale PZT network layer (LPNL) design method is proposed to overcome these challenges, by adopting a large-scale lightweight PZT network design method and network splitting–recombination based integration strategy. The developed LPNL offers the advantages of being large size, lightweight, ultra-thin, flexible, customized in shape and highly reliable. A series of extreme environmental tests are performed to verify the reliability of the developed LPNL under space service environment, including extreme temperature conditions, vibration at different flying phases, landing impact, and flying overload. Results show that the developed LPNL can withstand these harsh environmental conditions and presents high reliability and functionality.

Environmental and operational conditions effects on Lamb wave based structural health monitoring systems: A review

Lamb wave is widely recognized as one of the most encouraging tools for structural health monitoring (SHM) systems. In spite of many favourable characteristics of Lamb wave for SHM, real-world application of these systems is still quite limited. Beside the complexities derived from multi-modal, dispersive and multi-path characteristics of Lamb waves, one of the main challenges in Lamb wave based SHM is sensitivity of these systems to environmental and operational conditions (EOCs) parameters. This paper provides a state of the art review of the effects of EOCs parameters including: temperature, moisture, load, vibration and bonding (adhesive layer shear modulus and thickness, bond defects), on Lamb wave propagation. Moreover, this paper provides a summary of compensation strategies to account for EOCs effects as well as baseline free techniques. An objective is also to understand the future directions and areas requiring attention of the researchers.

Characterization of Ultrasonic Energy Diffusion in a Steel Alloy Sample with Tensile Force Using PZT Transducers

During the propagation of ultrasound in a polycrystalline material, ultrasonic energy losses due to the scattering at the boundaries between grains is usually described by the ultrasonic energy diffusion equation, and the boundaries of the grains in the material are influenced by the structural load. The aim of this research is to investigate the characterization of ultrasonic energy diffusion in a steel alloy sample under structural load by using lead zirconate titanate (PZT) transducers. To investigate the influence of structural load on ultrasonic energy diffusion, an experimental setup of a steel alloy plate under different tensile forces is designed and four samples with similar dimensions are fabricated. The experimental results of the four samples reveal that, during the loading process, the normalized ultrasonic energy diffusion coefficient fluctuates firstly, then decreases and at last increases as the tensile force increases. The proposed tensile force index shows a similar changing trend to the recorded displacement of the sample. Moreover, when the tensile force is less than the lower yield point or the sample deforms elastically, the index can be approximated by a cubic model. Therefore, the proposed tensile force index can be used to monitor the tensile force in the elastic deformation stage. Moreover, based on these findings, some force evaluation methods and their potential applications, such as the preloading detection of bolts, can be developed based on the linear relationships between the proposed index and the applied force.

Detection of Gaps in Concrete⁻Metal Composite Structures Based on the Feature Extraction Method Using Piezoelectric Transducers

A feature extraction methodology based on lamb waves is developed for the non-invasive detection and prediction of the gap in concrete–metal composite structures, such as concrete-filled steel tubes. A popular feature extraction method, partial least squares regression, is utilised to predict the gaps. The data is collected using the piezoelectric transducers attached to the external surface of the metal of the composite structure. A piezoelectric actuator generates a sine burst signal, which propagates along the metal and is received by a piezoelectric sensor. The partial least squares regression is performed on the raw sensor signal to extract features and to determine the relationship between the signal and the gap size, which is then used to predict the gaps. The applicability of the developed system is tested on two concrete-metal composite specimens. The first specimen consisted of an aluminium plate and the second specimen consisted of a steel plate. This technique is able to detect and predict gaps as low as 0.1 mm. The results demonstrate the applicability of this technique for the gap and debonding detection in concrete-filled steel tubes, which are critical in determining the degree of composite action between concrete and metal.

An Innovative Diagnostic Film for Structural Health Monitoring of Metallic and Composite Structures

A novel lightweight diagnostic film with sensors/actuators and a multiple-path wiring option using inkjet printing was developed. The diagnostic film allows for systematic, accurate, and repeatable sensor placement. Furthermore, the film is highly flexible and adaptable for placement on complex configurations. The film can be attached to the surface of the structure through a uniform secondary boundary procedure or embedded within the composite layup during curing. The surface-mounted film can simply be peeled off for repair or replacement without scratching or damaging the part. The film offers significant weight reduction compared to other available technologies. A set of extreme temperature, altitude, and vibration environment test profiles were carried out following the Radio Technical Commission for Aeronautics (RTCA) DO-160 document to assess the durability and performance of the diagnostic film for onboard application. The diagnostic film was shown to be durable and reliable in withstanding the variable operational and harsh environmental conditions of tests representing the conditions of regional aircraft.

Characterization of Ultrasound Energy Diffusion Due to Small-Size Damage on an Aluminum Plate Using Piezoceramic Transducers

During the propagation of ultrasonic waves in structures, there is usually energy loss due to ultrasound energy diffusion and dissipation. The aim of this research is to characterize the ultrasound energy diffusion that occurs due to small-size damage on an aluminum plate using piezoceramic transducers, for the future purpose of developing a damage detection algorithm. The ultrasonic energy diffusion coefficient is related to the damage distributed in the medium. Meanwhile, the ultrasonic energy dissipation coefficient is related to the inhomogeneity of the medium. Both are usually employed to describe the characteristics of ultrasound energy diffusion. The existence of multimodes of Lamb waves in metallic plate structures results in the asynchronous energy transport of different modes. The mode of Lamb waves has a great influence on ultrasound energy diffusion as a result, and thus has to be chosen appropriately. In order to study the characteristics of ultrasound energy diffusion in metallic plate structures, an experimental setup of an aluminum plate with a through-hole, whose diameter varies from 0.6 mm to 1.2 mm, is used as the test specimen with the help of piezoceramic transducers. The experimental results of two categories of damages at different locations reveal that the existence of damage changes the energy transport between the actuator and the sensor. Also, when there is only one dominate mode of Lamb wave excited in the structure, the ultrasound energy diffusion coefficient decreases approximately linearly with the diameter of the simulated damage. Meanwhile, the ultrasonic energy dissipation coefficient increases approximately linearly with the diameter of the simulated damage. However, when two or more modes of Lamb waves are excited, due to the existence of different group velocities between the different modes, the energy transport of the different modes is asynchronous, and the ultrasonic energy diffusion is not strictly linear with the size of the damage. Therefore, it is recommended that only one dominant mode of Lamb wave should be excited during the characterization process, in order to ensure that the linear relationship between the damage size and the characteristic parameters is maintained. In addition, the findings from this paper demonstrate the potential of developing future damage detection algorithms using the linear relationships between damage size and the ultrasound energy diffusion coefficient or ultrasonic energy dissipation coefficient when a single dominant mode is excited.

Impact Damage Localisation with Piezoelectric Sensors under Operational and Environmental Conditions

Guided-wave structural health monitoring (SHM) systems with piezoelectric sensors are investigated for localisation of barely visible impact damage in CFRP plates under vibration and different thermal conditions. A single baseline set is used in a delay-and-sum algorithm with temperature correction for damage localisation in a large temperature range. Damage localisation is also demonstrated under transient thermal conditions, with signals recorded while the temperature is rapidly decreased. Damage severity due to successive impact events is studied under constant temperature. Damage is also localised when the plate is subjected to random vibration.