Composite Sensors

Crosslink currently is engaged in innovative research to develop a real-time, lightweight structural health monitoring (SHM) and repair system for composite structures. SHM is a process of implementing a damage sensing strategy that is expected to prevent catastrophic failure of aircraft composite structures by predicting the onset of partial or complete failure. SHM can be used as a surveillance technique to monitor destructive versus nondestructive stresses as well as damage progression. This would lead to reduced maintenance and operational costs, reduced inspection costs, and improved aircraft readiness. The system also allows for potential self-repair at the molecular level through cooperative research with the University of Southern Mississippi.

The focus of Crosslink's program is to develop a sensor system that measures strain and acoustic emissions; and provides a measurable signal as a result. Inherently conducting polymers (ICPs) show a change in electrical conductivity under mechanical strain. Crosslink has developed easily processible ICPs with high conductivity ranging from 10^-3 to 10³ S/cm. Using these ICPs as sensors would drastically reduce the cost associated with existing sensing methods. Being a relatively new aeronautical material, very limited information is available on the mechanisms of aging and property degradation in the composites, which control the service life of the aircraft. Therefore, the sensing technique must be rugged and must be able to withstand severe operating conditions. These conditions include aerodynamic stresses, prolonged exposure to extreme temperatures, UV radiations and humidity. The sensor must be able to identify repetitive changes as well as sudden deformations in the composite material such as damage, cracks and delamination. In order to monitor structural degradation, Crosslink's SHM system incorporates multiple sensors into or onto composite structures, which can provide a real-time evaluation of the mechanical integrity of the three-dimensional composite structure without introducing structural defects, such as delamination, or impacting the structure's mechanical integrity. Ultimately, this system will utilize a wireless communication network within the aircraft, leading to significant weight savings and near real time monitoring capabilities.

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