Open Circuit Resonant (SansEC) Sensor for Composite Damage Detection and Diagnosis in Aircraft Lightning Environments

Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage and empennage structures, control surfaces and coverings. However, the potential damage from the direct and indirect effects of lightning strikes is of increased concern to aircraft designers and operators. When a lightning strike occurs, the points of attachment and detachment on the aircraft surface must be found by visual inspection, and then assessed for damage by maintenance personnel to ensure continued safe flight operations. In this paper, a new method and system for aircraft in-situ damage detection and diagnosis are presented. The method and system are based on open circuit (SansEC) sensor technology developed at NASA Langley Research Center. SansEC (Sans Electric Connection) sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect damage in composite materials. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. Unique electrical signatures are used for damage detection and diagnosis. NASA LaRC has both experimentally and theoretically demonstrated that SansEC sensors can be effectively used for in-situ composite damage detection

Wireless Temperature Sensing Method Using no Electrical Connections

A wireless temperature sensor includes an electrical conductor and a material spaced apart from the conductor and located within one or more of the responding electric field and responding magnetic field of the conductor. The conductor is electrically unconnected and is shaped for storage of an electric field and a magnetic field. In the presence of a time-varying magnetic field, the conductor resonates to generate harmonic electric and magnetic field responses, each of which has a frequency associated therewith. The material is selected such that it experiences changes in one of dielectric properties and magnetic permeability properties in the presence of a temperature change. Shifts from the sensor's baseline frequency response indicate that the material has experienced a temperature change

Open Circuit Resonant (SansEC) Sensor Technology for Lightning Mitigation and Damage Detection and Diagnosis for Composite Aircraft Applications

Traditional methods to protect composite aircraft from lightning strike damage rely on a conductive layer embedded on or within the surface of the aircraft composite skin. This method is effective at preventing major direct effect damage and minimizes indirect effects to aircraft systems from lightning strike attachment, but provides no additional benefit for the added parasitic weight from the conductive layer. When a known lightning strike occurs, the points of attachment and detachment on the aircraft surface are visually inspected and checked for damage by maintenance personnel to ensure continued safe flight operations. A new multi-functional lightning strike protection (LSP) method has been developed to provide aircraft lightning strike protection, damage detection and diagnosis for composite aircraft surfaces. The method incorporates a SansEC sensor array on the aircraft exterior surfaces forming a "Smart skin" surface for aircraft lightning zones certified to withstand strikes up to 100 kiloamperes peak current. SansEC sensors are open-circuit devices comprised of conductive trace spiral patterns sans (without) electrical connections. The SansEC sensor is an electromagnetic resonator having specific resonant parameters (frequency, amplitude, bandwidth & phase) which when electromagnetically coupled with a composite substrate will indicate the electrical impedance of the composite through a change in its resonant response. Any measureable shift in the resonant characteristics can be an indication of damage to the composite caused by a lightning strike or from other means. The SansEC sensor method is intended to diagnose damage for both in-situ health monitoring or ground inspections. In this paper, the theoretical mathematical framework is established for the use of open circuit sensors to perform damage detection and diagnosis on carbon fiber composites. Both computational and experimental analyses were conducted to validate this new method and system for aircraft composite damage detection and diagnosis. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. This paper also presents the shielding effectiveness along with the lightning direct effect test results from several different SansEC LSP and baseline protected and unprotected carbon fiber reinforced polymer (CFRP) test panels struck at 40 and 100 kiloamperes following a universal common practice test procedure to enable damage comparisons between SansEC LSP configurations and common practice copper mesh LSP approaches. The SansEC test panels were mounted in a LSP test bed during the lightning test. Electrical, mechanical and thermal parameters were measured during lightning attachment and are presented with post test nondestructive inspection comparisons. The paper provides correlational results between the SansEC sensors computed electric field distribution and the location of the lightning attachment on the sensor trace and visual observations showing the SansEC sensor's affinity for dispersing the lightning attachment

Antenna for near Field Sensing and Far Field Transceiving

An antenna includes a first electrical conductor that is shaped to form a spiral between its first and second ends that remain electrically unconnected such that the first electrical conductor so-shaped is maintained as an unconnected single-component open-circuit having inductance and capacitance. In the presence of a time-varying electromagnetic field, the first electrical conductor so-shaped resonates to generate a harmonic electromagnetic field response having a frequency, amplitude and bandwidth. A second electrical conductor includes a loop portion overlapping at least a portion of the spiral. The second electrical conductor is electrically isolated from the first electrical conductor. A radio frequency transceiver capable of transmitting and receiving electromagnetic energy is electrically coupled to the second electrical conductor

Multi-Layer Wireless Sensor Construct for Use at Electrically-Conductive Material Surfaces

A multi-layer wireless sensor construct is provided. The construct includes a first dielectric layer adapted to be attached to a portion of a first surface of an electrically-conductive material. A layer of mu metal is provided on the first dielectric layer. A second dielectric layer is provided on the layer of mu metal. An electrical conductor is provided on the second dielectric layer wherein the second dielectric layer separates the electrical conductor from the layer of mu metal. The electrical conductor has first and second ends and is shaped to form an unconnected open-circuit that, in the presence of a time-varying magnetic field, resonates to generate a harmonic magnetic field response having a frequency, amplitude and bandwidth

Lightning Protection and Detection System

A lightning protection and detection system includes a non-conductive substrate material of an apparatus; a sensor formed of a conductive material and deposited on the non-conductive substrate material of the apparatus. The sensor includes a conductive trace formed in a continuous spiral winding starting at a first end at a center region of the sensor and ending at a second end at an outer corner region of the sensor, the first and second ends being open and unconnected. An electrical measurement system is in communication with the sensor and receives a resonant response from the sensor, to perform detection, in real-time, of lightning strike occurrences and damage therefrom to the sensor and the non-conductive substrate material

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensor

Sol-Gel-Derived Hydroxyapatite-Carbon Nanotube/Titania Coatings on Titanium Substrates

In this paper, hydroxyapatite-carbon nanotube/titania (HA-CNT/TiO2) double layer coatings were successfully developed on titanium (Ti) substrates intended for biomedical applications. A TiO2 coating was firstly developed by anodization to improve bonding between HA and Ti, and then the layer of HA and CNTs was coated on the surface by the sol-gel process to improve the biocompatibility and mechanical properties of Ti. The surfaces of double layer coatings were uniform and crack-free with a thickness of about 7 μm. The bonding strength of the HA-CNT/TiO2 coating was higher than that of the pure HA and HA-CNT coatings. Additionally, in vitro cell experiments showed that CNTs promoted the adhesion of preosteoblasts on the HA-CNT/TiO2 double layer coatings. These unique surfaces combined with the osteoconductive properties of HA exhibited the excellent mechanical properties of CNTs. Therefore, the developed HA-CNT/TiO2 coatings on Ti substrates might be a promising material for bone replacement

Effect of Municipal Solid Waste Incineration Ash on Microstructure and Hydration Mechanism of Geopolymer Composites

The geopolymerization process is an appropriate way of disposing of municipal solid waste incineration fly ash (MSWIFA), and possesses the advantages of immobilizing the heavy metals and making full use of its pozzolanic properties in manufacturing green, cementitious materials. In this study, coal fly ash (FA) and metakaolin (MK) were used to prepare a geopolymer composite, with MK partially replaced by different proportions of MSWIFA through the alkali-activation method. The microstructure and hydration mechanism of the geopolymer composites containing MSWIFA were investigated through mercury intrusion porosimetry (MIP), scanning electron microscopy (SEM), and Fourier transform-infrared spectroscopy (FT-IR) tests; and the immobilization effect of the geopolymer paste on heavy metal ions was explored through inductively coupled plasma-atomic emission spectrometry (ICP-AES). The MIP analysis showed that the addition of MFARR had an overall degrading effect on the pore structure of the matrix. When the content of MSWIFA reached the maximum of 35%, the porosity and average pore diameter increased by 25% and 16%, respectively, corresponding to the case without MSWIFA. However, the pore size distribution exhibited an improving trend when the MFARR was increased from 15% to 25%. The SEM images revealed that the integrity of the micromorphology of the geopolymer mortar became weaker after adding MSWIFA. When the MSWIFA content was increased to 35%, the microstructural compactness decreased and more pores and microcracks appeared in the matrix. The FT-IR pattern study suggested that all the geopolymer composites had a similar internal structure, consisting of O-H, C-O, Si-O-Si, and Si-O-Al. The main component of the geopolymer paste hydrated at 28 d remained dominated by calcium silica-aluminate (C-A-S-H), when the MSWIFA ranged from 0% to 35%. Finally, the ICP-AES results showed that the leaching concentrations of the geopolymer paste of J-40 at 28 d for Cd, Cr, Cu, Pb, and Zn met the requirements of Chinese standards