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Technology, functionality and reliability of integrated ultrasonic microsystems for SHM in CFRP airplane structures

: Röllig, M.; Schubert, F.; Lautenschläger, G.; Franke, M.; Böhme, B.; Münch, S.; Meyendorf, N.

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Deutsche Gesellschaft für Zerstörungsfreie Prüfung e.V. -DGZfP-, Berlin:
4th International Symposium on NDT in Aerospace 2012. CD-ROM : November 13-15, 2012, Augsburg, Germany
Berlin: DGZfP, 2012 (DGZfP Proceedings BB 138-CD)
Paper Tu.3.B.3, 10 S.
International Symposium on NDT in Aerospace <4, 2012, Augsburg>
Konferenzbeitrag, Elektronische Publikation
Fraunhofer IZFP, Institutsteil Dresden ( IKTS-MD) ()

In this paper a novel approach for the integration of piezo sensor nodes into CFRP structures is presented. Functionality, manufacturability and reliability were experimentally investigated and supported by numerical modeling. For this purpose material characterization of the layered composite structures has been conducted to provide material data for the calculations. Finite Element Simulations were used to understand the structural mechanics during simultaneous sensor embedding and CFRP lamination and were also applied to risk estimation in terms of sensor and electronics reliability. Elastodynamic Finite Integration Technique (EFIT) was applied to study guided wave excitation and propagation inside multilayer CFRP structures and to determine the performance of sensors laminated into or applied on the surface of CFRP panels. The numerical results were then compared to experimental wave field measurements based on non-contact laser vibrometry. As a result the structure integration of the SHM sensor system was significantly improved by optimizing a) the efficiency of ultrasonic wave coupling to the CFRP body structure, b) the CFRP lamination process, and c) the reliability of integrated sensors and electronics. This systematic work was performed to increase the acceptance of structure integrated ultrasonic SHM systems and to reach higher technical readiness levels (TRL).