8
1 Smart Composite System Laboratory Smart Composite System Laboratory The University of Tokyo Structural Health Structural Health Monitoring of Aerospace Monitoring of Aerospace Composite Structures Composite Structures Presentation at APSS August 2, 2010 Kashiwa Campus, the University of Tokyo Nobuo Takeda Nobuo Takeda The University of Tokyo The University of Tokyo Dept. Advanced Energy Graduate School of Frontier Sciences and Dept. Aeronautics and Astronautics School of Engineering Smart Composite System Laboratory The University of Tokyo Boeing 787 Reusable Launch Vehicle of JAXA/ISAS Airbus A380 Structural Health Monitoring (SHM) is a key technology for safety assurance and maintenance cost reduction Increasing Use of Advanced Increasing Use of Advanced Composites in Aerospace Structures Composites in Aerospace Structures Courtesy by Airbus Courtesy by Boeing to reduce weight for energy saving Smart Composite System Laboratory The University of Tokyo Aluminum Aluminum Materials Used in Boeing 787 Aircraft Materials Used in Boeing 787 Aircraft CFRP 50% Al Alloys 20% Ti Alloys 15% Steel 10% Others 5% CFRP CFRP Sandwich GFRP Al Alloys Steel & Ti Alloys, Engine Pyron Courtesy by Boeing Smart Composite System Laboratory The University of Tokyo Feb. 2005, Newton Composite Materials and Structures are most important in Japanese aerospace industries Smart Sensing and Structural Health Monitoring are key technologies for safe operation and efficient maintenance for future aerospace structures Smart Composite System Laboratory The University of Tokyo Outline Outline (1) (1) Structural Health Monitoring Group, Structural Health Monitoring Group, NEDO Smart NEDO Smart Material/Structure System Program (FY1998 Material/Structure System Program (FY1998-2002) 2002) (2) (2) Structural Integrity Diagnosis and Evaluation of Structural Integrity Diagnosis and Evaluation of Advanced Composite Structures (ACS Advanced Composite Structures (ACS-SIDE) SIDE) Project, Project, METI METI Advanced Material & Processing Advanced Material & Processing for for Next Next-Generation Aircraft Structure Program Generation Aircraft Structure Program (FY2003 (FY2003- 2007) 2007) (3) Integrated High (3) Integrated High-Resolution Distributed Strain Resolution Distributed Strain Monitoring with Embedded Optical Fibers in Monitoring with Embedded Optical Fibers in Composite Composite St Stru ructures ctures (FY2007 (FY2007-) Smart Composite System Laboratory The University of Tokyo Health Monitoring Univ. Tokyo 10 Companies Active/Adaptive Structures Nagoya Univ. 4 Companies & Tokyo MMU Smart Manufacturing Osaka City Univ. 2 Companies Actuator Materials & Devices Tohoku Univ. 4 Companies & Univ. of Washington Demonstrator Program 4 Companies National Institute of Advanced Industrial Science and Technology Smart Structure Research Center METI(Ministry of Economy, Trade and Industry) NEDO(New Energy and industrial Technology Development organization) RIMCOF(R&D Institute of Metals & Composites for Future Industries) 5 Year Program From April 1998 To March 2003 Approximately 5 Million US Dollars per year NEDO Smart Material/Structure System Program NEDO Smart Material/Structure System Program

Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

Embed Size (px)

Citation preview

Page 1: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

1

Smart Composite System Laboratory The University of TokyoSmart Composite System Laboratory The University of Tokyo

Structural Health Structural Health Monitoring of Aerospace Monitoring of Aerospace

Composite StructuresComposite Structures

Presentation at APSSAugust 2, 2010

Kashiwa Campus, the University of Tokyo

Nobuo TakedaNobuo TakedaThe University of TokyoThe University of Tokyo

Dept. Advanced EnergyGraduate School of Frontier Sciences

andDept. Aeronautics and Astronautics

School of Engineering

Smart Composite System Laboratory The University of Tokyo

Boeing 787

Reusable Launch Vehicleof JAXA/ISAS

Airbus A380

Structural Health Monitoring (SHM) is a key technology for safety assurance and maintenance cost reduction

Increasing Use of Advanced Increasing Use of Advanced Composites in Aerospace StructuresComposites in Aerospace Structures

Courtesy by Airbus

Courtesy by Boeing

to reduce weight for energy saving

Smart Composite System Laboratory The University of Tokyo

Composites50%

Titanium15%

Other5%Steel

10%

Aluminum20%

CFRPCFRPサンドイッチ

GFRPアルミ合金

鋼・チタン エンジンパイロン

複合材

アルミ合金

チタン合金

鋼材その他

Composites50%

Titanium15%

Other5%Steel

10%

Aluminum20%

CFRPCFRPサンドイッチ

GFRPアルミ合金

鋼・チタン エンジンパイロン

複合材

アルミ合金

チタン合金

鋼材その他

Materials Used in Boeing 787 AircraftMaterials Used in Boeing 787 Aircraft

CFRP50%

Al Alloys20%

Ti Alloys15%

Steel10%

Others5%

CFRPCFRP SandwichGFRPAl AlloysSteel & Ti Alloys, Engine Pyron Courtesy by Boeing

Smart Composite System Laboratory The University of Tokyo

Feb. 2005, Newton

Composite Materials and Structures are most important in Japanese aerospace industries

Smart Sensing and Structural Health Monitoring are key technologies for safe operation and efficient

maintenance for future aerospace structures

Smart Composite System Laboratory The University of Tokyo

OutlineOutline(1)(1) Structural Health Monitoring Group,Structural Health Monitoring Group, NEDO Smart NEDO Smart

Material/Structure System Program (FY1998Material/Structure System Program (FY1998--2002)2002)

(2)(2) Structural Integrity Diagnosis and Evaluation of Structural Integrity Diagnosis and Evaluation of Advanced Composite Structures (ACSAdvanced Composite Structures (ACS--SIDE) SIDE) Project,Project, METIMETI Advanced Material & ProcessingAdvanced Material & Processingforfor NextNext--Generation Aircraft Structure ProgramGeneration Aircraft Structure Program(FY2003(FY2003--2007)2007)

(3) Integrated High(3) Integrated High--Resolution Distributed Strain Resolution Distributed Strain Monitoring with Embedded Optical Fibers in Monitoring with Embedded Optical Fibers in Composite Composite StStruructuresctures (FY2007(FY2007--))

Smart Composite System Laboratory The University of Tokyo

Health MonitoringUniv. Tokyo10 Companies

Active/Adaptive Structures

Nagoya Univ.4 Companies

& Tokyo MMU

Smart ManufacturingOsaka City Univ.

2 Companies

Actuator Materials& Devices

Tohoku Univ.4 Companies &

Univ. of Washington

DemonstratorProgram

4 Companies

National Institute of Advanced Industrial Science and TechnologySmart Structure Research Center

METI(Ministry of Economy, Trade and Industry)

NEDO(New Energy and industrial Technology Development organization)

RIMCOF(R&D Institute of Metals & Composites for Future Industries)

5 Year ProgramFrom April 1998To March 2003

Approximately5 Million US

Dollars per year

NEDO Smart Material/Structure System ProgramNEDO Smart Material/Structure System Program

Page 2: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

2

Smart Composite System Laboratory The University of Tokyo

Typical Damages in Composite LaminatesTypical Damages in Composite Laminates

Small-diameter FBG sensors were developed for detection of transverse cracks or the delamination in CFRP laminates.

Transverse Cracks

Delaminations

Typical Thickness of CFRP PrepregLayers: 125 μm

Diameter of Carbon Fiber: 5-8 μm

Smart Composite System Laboratory The University of Tokyo

Ref

ract

ive

Inde

x

10mm0.53μm

Polyimide CoatingCladding

Core

6.5μm40μm

52μm

SmallSmall--diameter Fiber Bragg Grating Sensordiameter Fiber Bragg Grating Sensor

FBGCore Cladding

Smart Composite System Laboratory The University of Tokyo

Cladding PolyimideCoating

50μm

0o Ply

90o Ply

Uncoatednormal FBG sensor

Polyimide-coatedsmall-diameter FBG sensor

Cladding: φ 125μm Cladding: φ 40μmPolyimide Coating: φ 52μm

CFRP Laminates with Embedded FBG SensorsCFRP Laminates with Embedded FBG Sensors

Smart Composite System Laboratory The University of Tokyo

Response of FBG Response of FBG Sensor to StrainSensor to Strain

λ0 λ1

IR

Incident Light

TransmittedLight

λ1 d=0.5μm

Reflection spectrum is narrowband.Strain determined from wavelength shift.

Incident Light Transmitted

Lightλ1λ2

λ3

λ0 λ1

IR

λ2 λ3

Reflection spectrum becomes broadband,which can be used for damage detection.

Uniform strain Non-uniform strain

Small-Diameter Optical Fiber

FBG0o Ply

0o Ply90o Ply

Transverse CracksTensile Load

Small-diameter FBG Sensors can be embedded close to transverse cracks without deteriorating the laminate.

λ1=C1d=C2ε

Smart Composite System Laboratory The University of Tokyo

Detection of Transverse CracksDetection of Transverse Cracks

Small-Diameter Optical Fiber

FBG Sensor

CFRP: T800H/3631Laminate configuration: quasi-isotropic [45/0/-45/90]s

GFRP TabA

A

Cross section at A-A50μm

Cladding

Polyimide Coating

90o Ply

-45o Ply

Embedded FBG sensor in –45o ply for detection of 90o transverse cracks

Smart Composite System Laboratory The University of Tokyo

Reflection Spectra at Various Tensile Strain LevelsReflection Spectra at Various Tensile Strain Levels

1551 1555 1553 1557 1553 1559 1553 1559

0.2

0.15

0.1

0.05

0

Ref

lect

ivity

Wavelength (nm)

(A) ε = 0.00%, ρ = 0.0cm-1 (D) ε = 1.10%, ρ = 7.1cm-1

(B) ε = 0.49%, ρ = 0.0cm-1 (E) ε = 1.31%, ρ = 12.7cm-1

(C) ε = 0.90%, ρ = 1.4cm-1

(A) (B) (C) (D) (E)

Crack density ρ vs. tensile strain ε. Reflection spectra measured under tensile loading.

0

5

10

15

0 0.5 1 1.5

Cra

ck D

ensi

ty (

cm-1

)

Strain (%)

(A) (B)(C)

(D)

(E)

Detection of Transverse CracksDetection of Transverse Cracks

Reflection spectrum was sensitively deformed with increase in crack density

Page 3: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

3

Smart Composite System Laboratory The University of Tokyo

0

0.2

0.4

0.6

0.8

1

1.2

1548 1550 1552 1554

Nor

mal

ized

Inte

nsity

Wavelength (nm)

Ld = 0mm

No. of Cycles = 0

1548 1550 1552 1554Wavelength (nm)

Ld = 5.2mm

No. of Cycles = 20 x 103

0

0.2

0.4

0.6

0.8

1

1.2

1548 1550 1552 1554

Nor

mal

ized

Inte

nsity

Wavelength (nm)

Ld = 7.4mm

No. of Cycles = 100 x 103

1548 1550 1552 1554Wavelength (nm)

Ld = 9.0mm

No. of Cycles = 1000 x 103

Detection of FreeDetection of Free--Edge Edge DelaminationDelamination in Composite in Composite Laminates with Embedded SmallLaminates with Embedded Small--Diameter FBG SensorDiameter FBG Sensor

Intensities of two peaks changed with the delamination growthOptical Loss: 0.4 dB

Smart Composite System Laboratory The University of Tokyo

Impact Damage Impact Damage Detection in Composite StructuresDetection in Composite Structures-- Building Block Approach Building Block Approach --

OPTICAL FIBER

STIFFENED PANEL

FY1998-1999

IMPACT

FY2000-2001 FY2001-2002

Specimen

Impact TestingMachine

SMALL-DIAMETER OPTICAL FIBER

SMALL PANEL CURVED STIFFENED PANELCOUPON

Smart Composite System Laboratory The University of Tokyo

0

0.1

0.2

0.3

0.4

0.5

0 100 200 300 400 500

Distance from impact location to sensor position ,mm

Arr

ival

tim

e o

f st

rain

resp

onse

s ,

ms

□ FBG sensor (Stiffener direction) ● Strain gauge (Stiffener direction) ○ Strain gauge (Orthogonal to stiffener)

● Predected impact position× Impact position□ Sensor position

Arrival Time vs. Distance from Impact Point(Impacted at Stiffener Flange)

Predicted Impact Point(Impacted at Stiffener Flange)

Prediction of Impact Point Using Dynamic FBG ResponsePrediction of Impact Point Using Dynamic FBG Response

Smart Composite System Laboratory The University of Tokyo

Impact Damage Detection –Small-Diameter Optical Fiber

Impact Damage Detection – AE

Damage Detection-BOTDR

Damage Detection – Smart Patch

Damage Suppression -SMA

Low Cost RTM/Health Monitoring

Length: 3 mDiameter: 1.5 m

Overview of Demonstrator

Damage Detection and Suppression DemonstratorDamage Detection and Suppression Demonstrator

Smart Composite System Laboratory The University of Tokyo

OUTSIDE VIEW INSIDE VIEW

EMBEDDED SMALL-DIAMETEROPTICAL FIBER SENSORS

Arrangement of SmallArrangement of Small--Diameter Optical Fibers Diameter Optical Fibers in Upper Panel for Impact Damage Detectionin Upper Panel for Impact Damage Detection

SKIN, STRINGER AND SKIN/STRINGER :20 Optical Fibers including 6 FBG Sensors

Smart Composite System Laboratory The University of Tokyo

Damage Detection and Suppression DemonstratorDamage Detection and Suppression DemonstratorUpper Panel with Embedded Small-Diameter Optical Fiber Sensors

Mid-panel with Embedded FBG SensorsSkin(CFRP)

Loading Fixture(Steel)

Support Fixture(Steel)

Frame(Al alloy)

Trimmable Optical Fiber Connectors

Installed

Mid-panel with Embedded FBG Sensors

Page 4: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

4

Smart Composite System Laboratory The University of Tokyo

Impact Damage Detection TestImpact Damage Detection Testin Damage Detection and Suppression Demonstratorin Damage Detection and Suppression Demonstrator

Actuators for Flexural Load

Impact Test Machine

Dead Weight for Gravity Compensation

Impact Response Measuring System

Fixed Reaction Wall

Smart Composite System Laboratory The University of Tokyo

Impact Damage Detection SystemImpact Damage Detection System

VISUALIZATION(by Takeda Lab, Univ. Tokyo)

ANALYSIS/EVALUATION(by Kawasaki Heavy Industries, Ltd.)

Smart Composite System Laboratory The University of Tokyo

OutlineOutline(1)(1) Structural Health Monitoring Group,Structural Health Monitoring Group, NEDO Smart NEDO Smart

Material/Structure System Program (FY1998Material/Structure System Program (FY1998--2002)2002)

(2)(2) Structural Integrity Diagnosis and Evaluation of Structural Integrity Diagnosis and Evaluation of Advanced Composite Structures (Advanced Composite Structures (ACSACS--SIDESIDE) ) Project,Project, METIMETI Advanced Material & ProcessingAdvanced Material & Processingforfor NextNext--Generation Aircraft Structure ProgramGeneration Aircraft Structure Program(FY2003(FY2003--2007)2007)

(3) Integrated High(3) Integrated High--Resolution Distributed Strain Resolution Distributed Strain Monitoring with Embedded Optical Fibers in Monitoring with Embedded Optical Fibers in Composite (FY2007Composite (FY2007--))

Smart Composite System Laboratory The University of Tokyo

ACSACS--SIDE ProjectSIDE ProjectPZTPZT--FBG Hybrid Active Damage Sensing SystemFBG Hybrid Active Damage Sensing System

Fuji Heavy Industries Hitachi CableUniv. TokyoTohoku Univ., AIST

0

5

10

15

20

25

30

35

1548 1549 1550 1551 1552

W ave leng th [nm ]

Tra

nsm

issi

on [

%] Filter 1 Filter 2

+ strain-strain

Lamb wave detection up to 1 MHzLamb wave detection up to 1 MHzAWG (arrayed waveguide grating) filterAWG (arrayed waveguide grating) filter

SAWDSAWDTMTM (Subaru Active Wave Detection) System(Subaru Active Wave Detection) System

SPIE Paper 6932-1

Smart Composite System Laboratory The University of Tokyo

Monitoring of Monitoring of DebondingDebonding at Critical Regions or Hot Spots at Critical Regions or Hot Spots of CFRP Skinof CFRP Skin--Stringer Stringer BondlinesBondlines

PZT FBG Artificial defect

(unit: mm)

15

5

500970

40

16.5 16.5

300

5

10

Skin

Hat-shape stringer

Skin & Stringer: CFRP quasi-isotropic laminates

Smart Composite System Laboratory The University of Tokyo

-40

-20

0

20

40

0 20 40 60 80 100

-40

-20

0

20

40

0 20 40 60 80 100

L = 0mm

L = 5mm

Time (μs)

Vol

tage

(m

V)

-40

-20

0

20

40

0 20 40 60 80 100

L = 7mm

-40

-20

0

20

40

0 20 40 60 80 100

L = 12mm40

0

-40

40

0

-40

40

0

-40

40

0

-40

0 20 40 60 80 100

5000

300

150

L = 0mm

L = 5mm

L = 7mm

L = 12mm

Freq

uenc

y

(kH

z)

0 20 40 60 80 100

5000

300

1505000

300

1505000

300

150

Arrival of the first peak became slower after debonding passed through FBG

Detected Lamb Waves with Growing Detected Lamb Waves with Growing DebondingDebonding(Bonded FBG (A))

Time (μs)

L

(A), (B)

(A) Bonded(B) Embedded

Page 5: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

5

Smart Composite System Laboratory The University of Tokyo

: Standard wavelet coefficient ijx ijx : Compared wavelet coefficient

( )∑ −=ij

ijijd

xxN

DI 21

calculated from all the distribution of the wavelet coefficients

Damage Index Damage Index DIDImax

max max

0

2 2

0 0

( ) ( )

( ) ( )

t t

tt t t t

t t

f t g tc

f t g t

=

=

= =

= =

⋅=

∑ ∑

f(t): Standard wavelet coefficient at 300kHzg(t): Compared wavelet coefficient at 300kHz

Correlation Coefficient Correlation Coefficient cc

5000

300

150

L = 0mm

0 20 40 60 80 100 Time (ms)

Freq

uenc

y (k

Hz)

5000

300

150

L = 0mm

Time (ms)

L = 7mm

0 20 40 60 80 100

Definition of Damage Index Definition of Damage Index DIDI and Correlation Coefficient and Correlation Coefficient cc

Smart Composite System Laboratory The University of Tokyo

0.6

0.8

1.0

1.2

0 2 4 6 8 10 120 2 4 8 126

Cor

rela

tion

Coe

ffici

ent

1.2

1.0

0.8

0.610

Debonding Length (mm)14

0

20

40

60

80

100

120

140

160

180

0 2 4 6 8 10 12 14

Dam

age

Inde

x

160

Debonding Length (mm)0 2 4 8 10 126

14012010080604020

0

0

2

4

6

8

10

12

14

0 2 4 6 8 10 12 14

Dam

age

Inde

x

14

Debonding Length (mm)

0 2 4 8 10 126 14

12

10

8

6

4

2

00

Debonding Length (mm)

0.6

0.8

1.0

1.2

0 2 4 6 8 10 12

Debonding Length (mm)

0 2 4 8 126

Cor

rela

tion

Coe

ffici

ent

1.2

1.0

0.8

0.6100

L

(A), (B)

Bonded FBG(A)

Embedded FBG(B)

DamageIndex

CorrelationCoefficient

CorrelationCoefficient

DamageIndex

180

Damage Index Damage Index DIDI and Correlation Coefficient and Correlation Coefficient cc as Functions of as Functions of DebondingDebonding LengthLength

Results by embedded FBG (B) changes rapidly around L = 6mm, which indicates that the debonding passed above the FBG (B).

Smart Composite System Laboratory The University of Tokyo

(1) Read the waveforms detected by the damage monitoring deviceSAWD Damage Diagnosis SoftwareSAWD Damage Diagnosis Software

Smart Composite System Laboratory The University of Tokyo

(2) Calculate the damage area by the damage diagnosis softwareSAWD Damage Diagnosis SoftwareSAWD Damage Diagnosis Software

Smart Composite System Laboratory The University of Tokyo

Design allowable

Residual cyclic number

(3) Predict the damage growth by the residual life prognosis softwareSAWD Damage Diagnosis SoftwareSAWD Damage Diagnosis Software

Smart Composite System Laboratory The University of Tokyo

Verification by SubVerification by Sub--Structure TestsStructure Tests

Amp.Device

PC

Removable

Installing & cabling withFBG sensors/PZT

The system set-up was simulated for practical use in inspection or maintenance field

On ground (ex. hangar) On board permanently

Connected to the device

Size: 4000 X 2000 X 400 mm

To removable connector

Removable connector

O.F. & PZT cables

Page 6: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

6

Smart Composite System Laboratory The University of Tokyo

Correlation Point ofPump Light and Probe Light

Feature of BOCDAHigh spatial resolution (5 cm in length: Normal Mode)

(2 mm in length: HR Mode)High speed sampling rate (10Hz)Multi-points strain sensing (random access)

The phases of the pump and the probe light waves change periodically, it make the correlation peak position on the fiber. At the correlation peak position, the pump and the probe light waves are synchronously frequency modulated and maintain the frequency difference.

Pump Light Prove Light

Freq

uenc

y

Optical Fiber

Strain

Distance

Inte

nsity

Probe Frequency

Strain

Distance

Inte

nsity

Probe Frequency

ACSACS--SIDE ProjectSIDE ProjectBOCDABOCDA HighHigh--Resolution Distributed Strain MeasurementResolution Distributed Strain Measurement

Mitsubishi Heavy Industries, University of Tokyo

SPIE Paper 6933-29

BOCDA Principle (Brillouin Optical Correlation Domain Analysis) developed by Professor Hotate

ΔνS=CSε+CTΔT

Smart Composite System Laboratory The University of Tokyo

Powersupply

Controlunit

Optical unit1. Bolted joint distributed strain monitoring

2. On-board type BOCDA system development3. Flight load monitoring using BOCDA system

Detect damage by distributed strain

Missing Fastener

Optical Fiber

Sensor

(2) On-board BOCDA system development

Structure life assessment

(3) Flight load monitoring using BOCDA system

Optical fiber sensor

BOCDABOCDA--SHM System DevelopmentSHM System Development

(1) Bolted portion monitoring

Monitor

Power Supply

Optical unit

Control unit

Monitor

Power Supply

Optical unit

Control unit

0

100

200

300

400

500

600

700

0 10 20 30 40 50 60 70 80 90

Time [sec]

Str

ain

[ue]

strain form BGS

Strain Gage

Smart Composite System Laboratory The University of Tokyo

BOCDA Distributed Strain Measurement ResultsBOCDA Distributed Strain Measurement Results

– It was observed the clear deference in distributed strain between the intact structure and that with a missing bolt.

⇒structure defects (missing bolt) was detectable by high spatial resolution BOCDA system.

-500

0

500

1000

1500

2000

10.7 11 11.3 11.6

Position [m]

Stra

in [με]

Intact#5 bolt removed

#5 bolt

X=11.0

X=11.3

Opticalfiber sensor

Strain gage

Smart Composite System Laboratory The University of Tokyo

<Flight condition>Pull upAlt: 15,000ft

<Measuring Condition>Dynamic sampling (60pt/sec)

On-board BOCDA system was successfully operated during flight conditions to assess structural load history

<Flight condition>Landing

<Measuring Condition>Dynamic sampling (60pt/sec)

-300-200-100

0100200300400

0 20 40 60 80 100

Time [sec]

Stra

in [με]

Strain from BOCDA

Strain Gage

-300-200-100

0100200300400

20 40 60 80 100

Time [sec]

Stra

in [με]

Strain from BOCDAStrain gage

Dynamic Flight Load MonitoringDynamic Flight Load Monitoring

Smart Composite System Laboratory The University of Tokyo

OutlineOutline(1)(1) Structural Health Monitoring Group,Structural Health Monitoring Group, NEDO Smart NEDO Smart

Material/Structure System Program (FY1998Material/Structure System Program (FY1998--2002)2002)

(2)(2) Structural Integrity Diagnosis and Evaluation of Structural Integrity Diagnosis and Evaluation of Advanced Composite Structures (ACSAdvanced Composite Structures (ACS--SIDE) SIDE) Project,Project, METIMETI Advanced Material & ProcessingAdvanced Material & Processingforfor NextNext--Generation Aircraft Structure ProgramGeneration Aircraft Structure Program(FY2003(FY2003--2007)2007)

(3) Integrated High(3) Integrated High--Resolution Distributed Strain Resolution Distributed Strain Monitoring with Embedded Optical Fibers in Monitoring with Embedded Optical Fibers in Composite (FY2007Composite (FY2007--))

Smart Composite System Laboratory The University of Tokyo

PPPPPP--BOTDABOTDA sensing systemsensing system

Neubrescope(Neubrex Co., Ltd)

Pre-pump Pulse Brillouin Optical Time Domain AnalysisDistributed strain measurement

Spatial resolution: 10 cm Sampling interval: 5 cmSensing range: > 1 km (whole length of optical fiber)

Page 7: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

7

Smart Composite System Laboratory The University of Tokyo

大規模構造物への適用 (VaRTM成形中)

供試体内埋め込み

Vacuum Bag

T-II

S-II

T-I

S-I

Ligh

t Sw

itch

OSA

Light Source

(Path Change)PPP-

BO

TDA

2.1m

Strain Measurement During Strain Measurement During VaRTMVaRTM (Vacuum(Vacuum--assisted Resin assisted Resin Transfer Molding)Transfer Molding) Process of CFRP Stiffened StructuresProcess of CFRP Stiffened Structures

PPP-BOTDA and FBG Strain Measurements in a Single Fiber

Small-diameter optical fiber with high refraction index difference was effective to reduce the optical loss due to embedment

Comparison of Strains by FBG and PPP-BOTDA Measurement

Fiber Embedment

Smart Composite System Laboratory The University of Tokyo

大規模構造物への適用 (VaRTM成形中)

-1 0 1 2 3-300

-200

-100

0

100

200

300

Distance (m)

Stra

in (μ

ε)

Residual Thermal Strain Distribution

FBG

Embedded Region

Strain Measurement During Strain Measurement During VaRTMVaRTM (Vacuum(Vacuum--assisted Resin assisted Resin Transfer Molding)Transfer Molding) Process of CFRP Stiffened StructuresProcess of CFRP Stiffened Structures

PPP-BOTDA and FBG Strain Measurements in a Single Fiber

Comparison of Strains by FBG and PPP-BOTDA Measurement

Smart Composite System Laboratory The University of Tokyo

Damage Detection in CFRP Sandwich StructuresDamage Detection in CFRP Sandwich Structures

S. Minakuchi, et al., Journal of Sandwich Structures and Materials, 9 (1), pp 9-33, 2007.

Optical fiber acts as nerve to detect residual facesheet dent

Key1. Non-uniform strain is induced in optical fiber

in damaged area2. Facesheet dent is relatively wide

A limited number of optical fibers are sufficient to monitor whole structure

Smart Composite System Laboratory The University of Tokyo

Dent and Strain Distribution Dent and Strain Distribution –– Theory and ExperimentsTheory and Experiments

Facesheet: CFRP UT500/#135 (Toho Tenax Co.,Ltd., [(0,90)3])

Core : AL 3/16 5052-.001, Thickness : 20 mm(Showa Aircraft Industry Co.)

Adhesive films : AF-163-2K (3M Co.)

Displacement rate : 0.5 mm/minMaximum displacement : 0.5, 1 mm

Residual dent and strainwas well reproduced

Smart Composite System Laboratory The University of Tokyo

Response Simulation of SpectrumResponse Simulation of Spectrum

Calculate strain distributionalong embedded fiber

Calculate spectrumdepending on

measurement point

Simulation procedureDamage right above

embedded optical fiber

How spectrum changes when damage is introduced?

Developed optical software

Width of spectrum depends on damage sizeSmart Composite System Laboratory The University of Tokyo

Damage Detection TestDamage Detection TestSchematic of specimen Experimental set-up

Quasi-static indentation loadings were applied to introduce

simulated low velocity impact damage

Five kinds of maximum displacement :1, 2, 3, 4, 6.5 mm

Response depending on damage size was investigatedResponse depending on damage size was investigated

Diameter 12.7 mm

Facesheet: T700S/2500, [0/90]3SCore: Al 1/4-5052-.001

Page 8: Boeing 787 Composite Structures - BRIDGE ... by Boeing Smart Composite System Laboratory The Universit y of Tok o Feb. 2005, Newton Composite Materials and Structures are most important

8

Smart Composite System Laboratory The University of Tokyo

ResultsResults -1 mm was applied-

Load-displacement curves

Top view of center of specimen

2D-plot of F-1dB

I II III IVV

VI

VII

VIII III

IIIIV V

VIVII

VIII

Residual dent depth0.3 mm

(Invisible)

One line nearest to loading pointresponded to invisible damage

Smart Composite System Laboratory The University of Tokyo

ResultsResults -2 mm was applied-Load-displacement curves

Residual dent depth0.8 mm

Number of responding linesand values of F-1dB increased,

as damage became large

Top view of center of specimen

I II III IV

III

IIIIV

2D-plot of F-1dB

V

VI

VII

VIII

VVI

VIIVIII

Smart Composite System Laboratory The University of Tokyo

ResultsResults -3 mm was applied-Load-displacement curves

Residual dent depth1.1 mm

Responses of VI and VII differed,confirming high resolution

of the proposed system

Top view of center of specimen

I II III IV

III

IIIIV

2D-plot of F-1dB

V

VI

VII

VIII

VVI

VIIVIII

Smart Composite System Laboratory The University of Tokyo

ResultsResults -6.5 mm was applied-

I II III IV

Load-displacement curves

Residual dent depth2.5 mm(Visible)

Occurrence of impactcan be detected

with high sensitivity

Top view of center of specimen

I II III IV

III

IIIIV

2D-plot of F-1dB

V

VI

VII

VIII

VVI

VIIVIII

Smart Composite System Laboratory The University of Tokyo

Application of SHM Technology to NearApplication of SHM Technology to Near--Future Future

Affordable Composite Aircraft and Affordable Composite Aircraft and SpacesraftSpacesraft

(1)(1) Structural Health Monitoring Group,Structural Health Monitoring Group, NEDO Smart NEDO Smart Material/Structure System Program (FY1998Material/Structure System Program (FY1998--2002)2002)

(2)(2) Structural Integrity Diagnosis and Evaluation of Structural Integrity Diagnosis and Evaluation of Advanced Composite Structures (ACSAdvanced Composite Structures (ACS--SIDE) SIDE) Project,Project, METIMETI Advanced Material & ProcessingAdvanced Material & Processingforfor NextNext--Generation Aircraft Structure ProgramGeneration Aircraft Structure Program(FY2003(FY2003--2007)2007)

(3) Integrated High(3) Integrated High--Resolution Distributed Strain Resolution Distributed Strain Monitoring with Embedded Optical Fibers in Monitoring with Embedded Optical Fibers in CompositeComposite StructuresStructures (FY2007(FY2007--))

Smart Composite System Laboratory The University of Tokyo

SHM Aerospace Industrial Steering Committee (SHMSHM Aerospace Industrial Steering Committee (SHM--AISC) AISC) SAE GSAE G--11 Committee11 Committee

• Manufacturers:– Boeing– Airbus– EADS– Embraer– Bombardier– Lochkeed Martin– FHI

• System Integrators:– BAE– Honeywell– Goodrich– GE

• Regulatory Agencies:– FAA– EASA– US AF– US Army

• Research Organizations:– Stanford University– Sandia National Lab– Air Force Research of Scientific Research– University of Tokyo– University of Sheffield– NASA– NRC Canada– RIMCOF

• Operators/Users:– ATA