Overview
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.
Funding
Results
Executive Summary:
The aim of MAGNASENSE project 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, an innovative inductive technique based on the inverse magnetostrictive effect was introduced and special tracking/recording software to monitor the structural integrity of composite structures was 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 process was followed, 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 correlate mechanical to magnetic readings.
- Development of appropriate algorithms and software supporting the magnetic flux sensing.
- Manufacturing of component scale demonstrator.
Within MAGNASENSE, a complete operational chain of prototype equipment, software and sensors was attempted to be developed, that enriches the technology fronts in structural health monitoring of CFRP structures. Self sensing of CFRP components is a major step towards improving reliability and performance of aircraft structural elements. The ability to reliably monitor developed strains during or after structural loading will greatly assist in reduction of aircraft weight, through lowering of safety factors, and minimization of aircraft downtime, by increasing inspection speed and enabling prompt isolation and quantification of damaged areas.