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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Enhancing In-Flight Structural Health Monitoring of Vertical Lift Vehicles Operating in an Urban Environment

In-situ airframe sensors have long been considered a potential solution for structural health monitoring that could change the design, certification, operation and maintenance paradigms of flight vehicles. In this approach, large networks of sensors covering the entire, or most of, an airframe throughout its operational lifetime would support real-time decisions on airworthiness and obviate the need to overbuild components or perform multiple cycles of structural qualification testing and inspections. This concept would go beyond the current practice of placing select sensors in strategic locations or relying on such sensors only during airframe qualification flights and inspections. For vehicles in the emerging urban air mobility space, reducing weight associated with overbuilds and shortening down-time associated with inspections are critical for improving safety and affordability. In practice, the wide-scale use of in-situ sensors as primary assurance for structural health has not been demonstrated to be feasible or the best solution. A sensor integration testbed was developed as a platform to evaluate the potential of multiple sensor types to enable decision making on airworthiness. We report on the initial runs of this testbed with multiple sensors attached to a common test article. Metal foil strain gauges, eddy current, fiber optic, guided wave (acoustic emission and ultrasonic)and carbon nanotube roving sensors were affixed to the test article. Baseline as well as post damage initiation and fatiguing data are presented and discussed. Despite the relative simplicity of the test article, the interpretation of the as-captured test data was generally not conclusive or did not have wide enough coverage. This result emphasizes the challenges and current limitations both in testing and the practical broad application of embedded sensors as the determinative elements in critical decision making on wide-scale structural health.

Vertical Lift Vehicles↗
NASA NTRSDate not supplied

Enhancing In-Flight Structural Health Monitoring of Vertical Lift Vehicles Operating in an Urban Environment

In-situ airframe sensors have long been considered a potential solution for structural health monitoring that could change the design, certification, operation, and maintenance paradigms of flight vehicles. In this approach, large networks of sensors covering the entire, or most of, an airframe throughout its operational lifetime would support real-time decisions on airworthiness and obviate the need to overbuild components or perform multiple cycles of structural qualification testing and inspections. This concept would go beyond the current practice of placing select sensors in strategic locations or relying on such sensors only during airframe qualification flights and inspections. For vehicles in the emerging urban air mobility space, reducing weight associated with overbuilds and shortening down-time associated with inspections are critical for improving safety and affordability. In practice, the wide-scale use of in-situ sensors as primary assurance for structural health has not been demonstrated to be feasible or the best solution. A sensor integration testbed was developed as a platform to evaluate the potential of multiple sensor types to enable decision making on airworthiness. We report on the initial runs of this testbed with multiple sensors attached to a common test article. Metal foil strain gauges, eddy current, fiber optic, guided wave (acoustic emission and ultrasonic) and carbon nanotube roving sensors were affixed to the test article. Baseline as well as post damage initiation and fatiguing data are presented and discussed. Despite the relative simplicity of the test article, the interpretation of the as-captured test data was generally not conclusive or did not have wide enough coverage. This result emphasizes the challenges and current limitations both in testing and the practical broad application of embedded sensors as the determinative elements in critical decision making on wide-scale structural health.

Vertical Lift Vehicles↗
NASA NTRS2008

Fiber Optic Sensing Monitors Strain and Reduces Costs

In applications where stress on a structure may vary widely and have an unknown impact on integrity, a common engineering strategy has been overbuilding to ensure a sufficiently robust design. While this may be appropriate in applications where weight concerns are not paramount, space applications demand a bare minimum of mass, given astronomical per-pound launch costs. For decades, the preferred solution was the tactic of disassembly and investigation between flights. Knowing there must be a better way, Dr. Mark Froggatt, of Langley Research Center, explored alternate means of monitoring stresses and damage to the space shuttle. While a tear-it-apart-and-have-a-look strategy was effective, it was also a costly and time consuming process that risked further stresses through the very act of disassembly and reassembly. An alternate way of monitoring the condition of parts under the enormous stresses of space flight was needed. Froggatt and his colleagues at Langley built an early-warning device to provide detailed information about even minuscule cracks and deformations by etching a group of tiny lines, or grating, on a fiber optic cable five-thousandths of an inch thick with ultraviolet light. By then gluing the fiber to the side of a part, such as a fuel tank, and shining a laser beam down its length, reflected light indicated which gratings were under stress. Inferring this data from measurements in light rather than in bonded gauges saved additional weight. Various shuttle components now employ the ultrasonic dynamic vector stress sensor (UDVSS), allowing stress detection by measuring light beamed from a built-in mini-laser. By measuring changes in dynamic directional stress occurring in a material or structure, and including phase-locked loop, synchronous amplifier, and contact probe, the UDVSS proved especially useful among manufacturers of aerospace and automotive structures for stress testing and design evaluation. Engineers could ensure safety in airplanes and spaceships with a narrower, not overbuilt, margin of safety. For this development, in 1997, Discover Magazine named Froggatt a winner in the "Eighth Annual Awards for Technological Innovation" from more than 4,000 entries.

Source record↗