The aim of MAGNASENSE was to develop the appropriate smart maintenance technologies, using magnetostrictive sensors, in order to enable self-sensing of the strain field developed in components manufactured by CFRP. For this reason, all the hardware (embedded sensors – sensing elements etc.) and software (transformation of measurements to strain readings, inspection supporting software, initial correlation of strain measurements to internal damage etc.) to enable sensing and monitoring of the structural integrity of composite structures were developed. At the end of the project, a component scale demonstrator was manufactured (damaged stiffened panel repair with a bonded composite patch including embedded MsS), for the evaluation of the developed smart maintenance methodology. In order to succeed these goals, a five-step development and demonstration process is proposed, comprising of:

• Identification of appropriate strain sensitive magnetic wires (Magnetostrictive Sensor – MsS) to be applied to composite structures,
• Development of a non-contact magnetic flux sensor arrays for quick scanning and strain mapping of the composite structures,
• Numerical simulation of arrays of sensing elements, to couple mechanical to magnetic readings,
• Development of appropriate algorithms and software supporting the magnetic flux sensing and.
• Manufacturing of component scale demonstrator. MAGNASENSE will produce a complete operational chain of prototype equipment, software and sensors that will revolutionise the technology for structural health monitoring of CFRP structures.

It was expected that, by integrating self-sensing capabilities to CFRP structures, a direct reduction of maintenance requirements and costs will be achieved, while increasing structural reliability, thus assisting in increasing of EU manufactured aircraft competitiveness, greening of aircraft operations and maintenance activities and reduction of aircraft operations and maintenance costs.