Newly developed advanced aircraft structures are utilizing composite technology for improving stiffness, strength and weight properties. Such structures are commonly found in inaccessible regions where current NDE techniques are limited. The development of low profile, distributed, embeddable, real-time, optical fiber sensors capable of
detecting the onset of composite failure in aircraft structures would eliminate a significant portion of related maintenance costs. Notable composite failures that are difficult to assess include delaminations and moisture ingression issues. Optical fiber-based sensors add the inherent advantages of being lightweight, low profile, immune to EMI, resistant to harsh environments, and highly sensitive to a variety of physical and chemical measurements. Optical fiber-based sensors can also be embedded directly into the composite part during
manufacturing and co-cured. This creates a monitoring system that has little impact on the properties of the final part while providing significant benefits.
Fiber optics embedded in composite honeycomb panels were fabricated and tested using ground - air - ground thermal cycles to determine moisture ingression monitoring capabilities of the sensors. Two different types of moisture sensing fiber optics were measured. One type of installed moisture sensor is based off of a Bragg grating system, while the other moisture sensor is based off of a long period grating system. Presented herein is a comparison of the two different types of fiber optic sensors that monitored the moisture ingression in honeycomb panels.
Luna Innovations has developed a prototype 8-channel fiber optic sensor system to demonstrate fiber optic sensor operation in flight environments. As an intial flight demonstration, long period grating (LPG) relative humidity sensors along with extrinsic Fabry-Perot interferometric (EFPI) pressure and temperature sensors were installed in an aging Delta 767-300ER jet. The fiber optic signal-conditioning system is a multi-purpose platform that can also be used to operate other types of fiber optic LPG and EFPI sensors, including strain gages, metal-ion corrosion sensors, and fiber Bragg grating (FBG) sensors. The system configuration and operation is described.
A primary concern with composite repair patches is the potential degradation of load transfer capabilities due to aging and environmental effects. The development of low profile, distributed, embeddable, real-time, optical fiber sensors capable of detecting the onset of patch delamination on repaired regions of the aircraft would eliminate a significant portion of the related maintenance costs as well as improve confidence levels in the technology. The presented sensing system is comprised of optical fiber long period gratings (LPGs) for chemical measurement and Bragg gratings for strain measurement. The sensors can be multiplexed together to monitor the structural health of the patch system and status of any remaining damage in the parent structure. The LPG sensors operate based on specially designed sensing coatings which cause a measurable change in the refractive index 'seen' by the LPG in the presence of target molecules. In this configuration, LPGs can be used to detect moisture infiltration and other chemical changes within a localized environment. Complementary to the long period grating, Bragg grating strain sensors can be fabricated on the same optical fiber to measure load transfer and composite delamination in patches used to repair cracks that occur in aging aircraft.
Previously, the results of embedding multi-axis fiber gratings into adhesively bonded joints were discussed. This paper presents more information on the testing of the adhesive joints and techniques employed to successfully embed a fiber grating sensor into such structures. These techniques include orienting the fiber, marking its orientation, and preparing it for embedment into the adhesive. Also discussed are strain relief methods for the egress of the fiber.
Fiber optic grating sensors written into polarization preserving optical fiber may be used to monitor multidimensional strain fields in composite materials. This paper provides an overview of the characterization and test of multiaxis fiber grating sensors formed by writing 1300 and 1550 nm fiber gratings into polarization preserving optical fiber. A discussion of the usage of these multiaxis fiber grating sensors to measure two and three dimensional strain fields will be made. A brief review of practical applications of the technology to measure shear strain, transverse strain gradients as well as axial and traverse strain will be made with emphasis on aerospace and civil structure applications.
Most fiber grating sensor technology that has been developed to support strain sensing involves the measurement of axial strain. Fiber grating sensors are however capable of monitoring transverse as well as axial strain. This paper reviews a series of applications of this technology that are of particular interest to aerospace applications.
The use of adhesive joints in aerospace structures is becoming increasingly important. From this, arises the problem of assessing joint integrity quickly, non- intrusively, accurately, and inexpensively. Current methods of assessing joint integrity, such as ultrasonics and x- rays, are time intensive and difficult to interpret. Blue Road Research's solution to monitoring adhesive joint integrity quickly and accurately is to embed non-intrusive, multidimensional optical fiber grating strain sensors into or adjacent to the joints. Aluminum double lap adhesive joints were instrumented with the multi-axis grating strain sensors into or adjacent to the joints. Aluminum double lap adhesive joints were instrumented with the multi-axis senors and subjected to tension and fatigue test. Each specimen contained one sensor located either near the bond, embedded at the edge of the bond, or embedded towards the inner bond area. The joints with senors embedded into the adhesive showed minimal strength degradation. Basically, the multiaxis fiber grating strain sensors were found to provide information about transverse strain, axial strain, and transverse strain gradients that can provide important information throughout the adhesive joint. By changing the orientation of the sensor, shear strain and its effects can be clearly measured.
Fiber Bragg grating sensors generally consist of a single grating written in a low-birefringent optical fiber. The wavelength shift of the peak in the reflected spectrum from these sensors can be used to measure a single component of strain or a change in temperature [Lawrence, 1997]. Fibers are also available with a significant enough birefringence to maintain the polarization state along great lengths and through many turns. This 'polarization maintaining' fiber is commercially available through several companies and in several configurations (including different cladding material and wavelength shift). The grating usually extends approximately 3 mm - 5 m in length. Udd gives a detailed explanation of fiber optics, Bragg gratings and birefringence [Udd, 1991]. As light from an LED is passed through the fiber, only the wavelength consistent with the grating period will be reflected back towards the source. All other wavelengths will pass through. The reflected spectrum will shift as the fiber is strained along its axis at the grating location. Strain or temperature changes at any other location have negligible effect on the wavelength encoded data output. When the Fiber Bragg grating single-axis sensor (termed fiber hereafter) is strained transversely the wavelength will separate into two distinct peaks according to a mathematical relationship defined by Lawrence and Nelson [Lawrence, Nelson et al. 96]. Using these Fiber Bragg grating fibers a corrosion sensor which measures the rate of material was developed. The principle behind this newly developed corrosion sensor is to pre-stress the fiber with a known load. The load is applied by inducing a uniform hoop stress through pressure fitted cylinders around the fiber. This induced stress creates a broadening of the reflected spectrum until the bifurcation of the reflected intensity peaks is distinguishable. As the material from the outer cylinder corrodes away the applied stress will be relieved. Finally, when no load is achieved, the reflected spectrum will have a single peak centered around the nominal Bragg grating wavelength. If a polarizing-maintaining 3-axis grating is used then the sensor would be even more sensitive, having two distinct peaks in each wavelength regime which shift.
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