Embedded Fiber Bragg Grating Sensors for Monitoring Temperature and Thermo-Elastic Deformations in a Carbon Fiber Optical Bench.

A composite optical bench made up of Carbon Fiber Reinforced Polymer (CFRP) skin and aluminum honeycomb has been developed for the Tunable Magnetograph instrument (TuMag) for the SUNRISE III mission within the NASA Long Duration Balloon Program. This optical bench has been designed to meet lightweight and low sensitivity to thermal gradient requirements, resulting in a low Coefficient of Thermal Expansion (CTE). In addition to the flight model, a breadboard model identical to the flight one has been manufactured, including embedded fiber Bragg temperature and strain sensors. The aim of this is to explore if the use of distributed fiber Bragg gratings (FBGs) can provide valuable information for strain and temperature mapping of an optical instrument on board a space mission during its operation as well as its on-ground testing. Furthermore, surface-mounted strain FBG sensors and thermocouples have been installed in the optical bench for intercomparison purposes. This paper presents the results obtained from a thermal vacuum test consisting of three thermal cycles with stabilization steps at 100 °C, 60 °C, 20 °C and -20 °C. Experimental results provide information about how FBG embedded temperature sensors can provide a proper and quick response to the temperature changes of the optical bench and that embedded FBG strain sensors are able to measure micro-deformation induced in a close-to-zero CTE optical bench.

Icing Condition Predictions Using FBGS.

Icing is a hazard which is important for the aerospace industry and which has grown over the last few years. Developing sensors that can detect the existence not only of standard icing conditions with typically small droplet size, but also of Supercooled Large Droplet (SLD) conditions is one of the most important aims in order to minimize icing hazards in the near future. In the present paper a study of the Fiber Bragg Grating Sensors' (FBGSs) performance as a flight icing detection system that predicts the conditions of an icing cloud is carried out. The test matrix was performed in the INTA Icing Wind Tunnel (IWT) with several icing conditions including SLD. Two optic fibers with 16 FBGS in total were integrated in the lower and upper surface of an airfoil to measure the temperature all over the chord. The results are compared with a Messinger heat and mass balance model and the measurements of the FBGS are used to predict the Liquid Water Content (LWC) and Ice Accretion Rate (IAR). Finally, the results are evaluated and a sensor assessment is made. A good correlation was observed between theoretical calculations and test results obtained with the FBGS in the IWT tests. FBGS proved to detect the beginning and end of ice accretion, LWC and IAR quickly and with good precision.

Optical sensing of the fatigue damage state of CFRP under realistic aeronautical load sequences.

We present an optical sensing methodology to estimate the fatigue damage state of structures made of carbon fiber reinforced polymer (CFRP), by measuring variations on the surface roughness. Variable amplitude loads (VAL), which represent realistic loads during aeronautical missions of fighter aircraft (FALSTAFF) have been applied to coupons until failure. Stiffness degradation and surface roughness variations have been measured during the life of the coupons obtaining a Pearson correlation of 0.75 between both variables. The data were compared with a previous study for Constant Amplitude Load (CAL) obtaining similar results. Conclusions suggest that the surface roughness measured in strategic zones is a useful technique for structural health monitoring of CFRP structures, and that it is independent of the type of load applied. Surface roughness can be measured in the field by optical techniques such as speckle, confocal perfilometers and interferometry, among others.

Fiber Bragg Gratings Sensor Strain-Optic Behavior with Different Polymeric Coatings Subjected to Transverse Strain.

This research work is based on a previous study by the authors that characterized the behavior of FBG sensors with a polyimide coating in a structural monitoring system. Sensors applied to structural health monitoring are affected by the presence of simultaneous multidirectional strains. The previous study observed the influence of the transverse strain (εy) while keeping the longitudinal strain constant (εx), where the x direction is the direction of the optical fiber. The present study develops an experimental methodology consisting of a biaxial test plan on cruciform specimens with three embedded FBG sensors coated with polyimide, acrylate, and ORMOCER®. Applying the Strain-Optic Theory as a reference, a comparison of the experimental values obtained with the different coatings was studied. This experimental work made it possible to study the influence of the transverse strain (εy) on the longitudinal measurements of each FBGS and the influence of the coating material. Finally, the calibration procedure was defined as well as K (strain sensitivity factor) for each sensor.

Novel Electromagnetic Characterization Methods for New Materials and Structures in Aerospace Platforms.

The tendency over the last decades in the aerospace industry is to substitute classic metallic materials with new composite materials such as carbon fiber composites (CFC), fiber glass, etc., as well as adding electronic devices to ensure the safety and proper platform operation. Due to this, to protect the aircraft against the Electromagnetic Environmental Effects (E3), it is mandatory to develop accurate electromagnetic (EM) characterization measurement systems to analyze the behavior of new materials and electronic components. In this article, several measurement methods are described to assess the EM behavior of the samples under test: microstrip transmission line for a surface current analysis, free space to obtain intrinsic features of the materials and shielding effectiveness (SE) approaches to figure out how well they isolate from EM fields. The results presented in this work show how the different facilities from the National Institute of Aerospace Technology (INTA) are suitable for such purposes, being capable of measuring a wide variety of materials, depending on the type of test to be carried out.

Surface Irregularity Factor as a Parameter to Evaluate the Fatigue Damage State of CFRP.

This work presents an optical non-contact technique to evaluate the fatigue damage state of CFRP structures measuring the irregularity factor of the surface. This factor includes information about surface topology and can be measured easily on field, by techniques such as optical perfilometers. The surface irregularity factor has been correlated with stiffness degradation, which is a well-accepted parameter for the evaluation of the fatigue damage state of composite materials. Constant amplitude fatigue loads (CAL) and realistic variable amplitude loads (VAL), representative of real in- flight conditions, have been applied to "dog bone" shaped tensile specimens. It has been shown that the measurement of the surface irregularity parameters can be applied to evaluate the damage state of a structure, and that it is independent of the type of fatigue load that has caused the damage. As a result, this measurement technique is applicable for a wide range of inspections of composite material structures, from pressurized tanks with constant amplitude loads, to variable amplitude loaded aeronautical structures such as wings and empennages, up to automotive and other industrial applications.