A Structural Health Monitoring System for Bond Line Flaws Detection on a Full-Scale Wingbox Section Demonstrator

Abstract

In recent years, there has been a significant increase in the use of structural health monitoring (SHM) technologies as systems for monitoring the integrity of aircraft’s structures. The use of compact and embeddable sensor networks, like the ones based on fibre optics (FO), is particularly attractive from the perspective of releasing an integrated structural system with intrinsic sensing capacity. Usually, an SHM system architecture is completed by a dedicated algorithm that processes the data gathered from the sensors to elaborate on the level of damage currently suffered by the structure, with the further possibility of providing information to the relevant specialists involved with its supervision. One of the main SHM applications that is attracting major interest is related to the inspection and detection of anomalies in bonded joints, which is extremely relevant in many composite realizations. Aeronautical regulations allow the use of bonded joints on an aircraft’s primary structure but require the implementation of a means to ensure their absolute safety, such as the introduction of further mechanical links aimed at stopping the propagation of a possible flaw or the availability of Non-Destructive Inspection (NDI) systems to prove the absence of relevant damaged areas. Generally, the main typical defects occurring during the manufacturing of bonded joints include adhesive curing, kissing bonds, poor porosity, and poor surface preparation. The current NDI systems more widely used and available to detect defects are still inaccurate due to the lack of standard procedures for the creation of representative defects in a controlled manner, which would allow for the development of reliable methodologies and tools able to ensure the safety of a bonded joint, as required by safety regulations. This paper shows the results relative to the implementation of an SHM system developed by the Italian Aerospace Research Centre (CIRA) aimed at monitoring the bonding lines between spar caps and panels of a typical composite wingbox section and detecting faults in location and length. The work was performed during typical ground static tests by using a fibre optical sensing network embedded within relevant adhesive paste layers during the manufacturing process of the structure. In the reported investigation, the SHM system assumed the function of an NDI system tool. The results show that the developed SHM system has good reliability for the detection of both the position and size of damage areas that were artificially inserted within the test article during the bonding phase, showing its potential as a candidate to be used as a tool to verify the conditions of a bonded joint, as required by aviation authorities’ regulations.