MAGNASENSE

Magnetostrictive sensor applications for self-sensing of composite structures

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 Obiettivo del progetto (Objective)

'The aim of MAGNASENSE is 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, ispection supporting fotware, initial correlation of strain measurements to internal damage etc.) to enable sensing and monitoring of the structural integrity of composite structures will be developed. At the end of the project, a component scale demonstrator will be 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: (a) Identification of appropriate strain sensitive magnetic wires (Magnetostrictive Sensor – MsS) to be applied to composite structures, (b) Development of a non-contact magnetic flux sensor arrays for quick scanning and strain mapping of the composite structures, (c) Numerical simulation of arrays of sensing elements, to couple mechanical to magnetic readings, (d) Development of appropriate algorithms and software supporting the magnetic flux sensing and (e) 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 is 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.'

Introduzione (Teaser)

The aerospace industry is actively pursuing research to decrease operating costs while increasing safety and sustainability. Novel non-contact structural health monitoring based on embedded strain-sensitive magnetic wires addresses all issues cost effectively.

Descrizione progetto (Article)

With increasing globalisation has come a significant increase in air traffic over the past decades, and all predictions suggest it will continue to rise over the next two decades. Improved non-destructive inspection technologies are critical to competitiveness and sustainability. They can better detect defects and damage early, reducing time out for maintenance and costs of repairs. They also facilitate reductions in the weight associated with incorporation of additional safety features and thus decrease the load the planes carry and associated fuel consumption and emissions.

With EU support of the MAGNASENSE (Magnetostrictive sensor applications for self-sensing of composite structures) project, scientists developed smart maintenance technologies for strong and lightweight carbon fibre-reinforced (CFR) composite structures. They are based on strain-sensitive magnetic wires knitted into a metallic mesh and embedded in the CFR composite.

Non-contact magnetic flux sensing arrays scan and map the strain in the composite structures exploiting perhaps the most innovative feature of the system, optical tracking. This is accomplished with an infrared (IR) camera and a transducer with an attached IR light-emitting diode (LED). The LED guides the camera in localising the inspection site. A data acquisition system records the signal and converts it to a numeric format for analysis, all with wireless technologies.

All software and hardware combine to form a sophisticated sensing system for structural health monitoring of CFR composites. Accuracy is enhanced by advanced filtering algorithms. An image correlation tool using the optical metrology compares the structure's surface in reference and test conditions, providing a full-field strain signature. The MAGNASENSE system efficiently indicated areas of potential damage in a test of a component-scale demonstrator, a damaged stiffened panel repaired with a bonded composite patch.

The method provides indications of internal damage quickly, reliably and cost effectively in a non-contact manner. Partners expect to commercialise the MAGNASENSE system very quickly, significantly increasing the global competitiveness of the EU's aerospace industry and the entire supply chain for the product. Widespread uptake will also make an important contribution to the safety and sustainability of flight.