Non-destructive evaluation (NDE) methods, like ultrasonic inspection, face numerous challenges detecting defects within thin laminates. Short backwall distances paired with wave scattering and high attenuation caused by innate properties of stacked laminates result in difficulties with distinguishing sub-surface defects, such as delamination from geometric features. To improve the effectiveness of ultrasonic inspections for thin composite laminates the authors have implemented a multi-step approach to predict wave propagation behavior. This plan focuses on the use of finite element methods to simulate wave propagation behavior utilizing a single element transducer: (i) in water; (ii) in isotropic materials; (iii) in thin composite laminates. Analytical verification based on the Fresnel approximation was performed for ultrasonic wave propagation in water prior to modeling scenarios with isotropic materials and thin composites. In addition, experimental validation was performed in parallel to gauge the accuracy of all simulations. Initial computational results using a single element transducer for on-axis pressure measurements showed that acoustic elements were well suited for modelling water paths due to their computational efficiency and accuracy when paired with continuum stress elements. Preliminary experimental results showed it was possible to physically detect defects in both isotropic and composite material cases. The authors believe that computational models can be used for evaluating complex ultrasonic signals, aiding in the development of new ultrasonic inspection techniques for thin composite structures.
Structural load monitoring of wind turbines is becoming increasingly important due increasing turbine size and offshore
deployment. Rotor blades are key components that can be monitored by continuously measuring their deflection and
thereby determining strain and loads on the blades. In this paper, a method is investigated for monitoring blade
deformation that utilizes micro-electromechanical systems (MEMS) comprising triaxial accelerometers, magnetometers
and gyroscopes. This approach is demonstrated using a cantilever beam instrumented with 5 MEMS and 4 strain gauges.
The measured changes in angles obtained from the MEMS are used to determine a deformation surface which is used as
an input to a finite element model in order to estimate the strain throughout the beam. The results are then verified by
comparison with strain gauge measurements.
Fatigue crack detection and quantification is by far the most challenging task in Structural Health Monitoring (SHM). In
the past decade numerous techniques were developed to detect and quantify fatigue damages. Fatigue loading leads to
fatigue crack development in metals and delamination growth in composites. It has been found that different techniques
are suitable for different damage development. Hence, the selection of the appropriate analysis methodologies pertaining
to different problems is crucial. At the same time there has been an effort to reduce the power requirement for data
analysis. This in turn triggered the idea of developing low power damage detection algorithms. In this paper a comparison between different damage detection techniques are presented and problems with different materials and structural geometries are considered. Three damage detection techniques were selected and evaluated.
The primary objective of this study was to demonstrate the effectiveness of various strain measurement techniques at
detecting the disbonding of a composite repair patch and then using this information to validate a new capacitance based
disbond detection technique. The instrumented repair patch was parametrically designed with the help of Finite Element
Analysis (FEA) software to have a stress concentration at its tip. This stress concentration was designed to produce a
disbond during fatigue testing, without the need for the introduction of any foreign material to create an artificial disbond
condition. The aluminum substrate was grit blasted and the instrumented patch was bonded using FM®73 adhesive, and
was cured following the recommendations of the manufacturer. The geometric characteristics of the patch followed
standard repair guidelines for such variables as material selection, taper angles and loading conditions, with the
exception of the area designed for premature disbond. All test specimens were inspected using non-destructive testing
technique (ultrasound pulse echo) to guarantee that no disbonding had occurred during curing of the specimen. The
specimens were placed under fatigue loading to induce a disbond condition between the aluminum substrate and the
patch. The specimens were cyclically loaded and strain gauges bonded to strategic locations on the aluminum and
composite patch surface to be able to measure changes in surface strains as the disbond progressed. A Digital Image
Correlation (DIC) system was also used to measure full field strains over the gauge length of the coupon. The DIC
results were compared with the strain gauge data and were used to provide a qualitative measure of the load transfer in
the bonded specimen, which clearly demonstrated the change in surface strain that occurred as the composite patch
disbonded from the aluminum substrate. Thermoelastic Stress Analysis (TSA) was also used to measure surface strains
on the composite patch. Thermoelastic stress analysis proved to be the most sensitive technique for experimentally
monitoring the disbond process in real time. Failure analysis of the specimens using optical microscope techniques was
performed to determine the type of failure between the patch and the substrate. The results of this work will serve to test
the different types of sensors available for the design and manufacturing of a "Smart Patch" for aircraft structure
applications.
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