MAINTENANCE: DIAGNOSTICS, REPAIR, PROGNOSIS
Main objective is to develop a real time and onboard damage diagnosis system (also known as Structural Health Monitoring – SHM) for next generation condition-based maintenance of hybrid structural joints.
This will be achieved by:
- Development of representative structural models validated by mechanical testing
- Development and structural integration of novel sensors for SHM applications
- Evaluation, selection and development of SHM methods for damage diagnostics
- Experimental validation of SHM methods
The outcomes should provide strategies for SHM and repair of metal-to-metal, metal-to-composite and (thermoplastic) composite-to-composite material combinations to enhance cost-competitive joints in line with circular economy concepts.
SUSTAINair incorporates two key enabling technologies for maintenance:
Design for improved MRO operations of morphing wing structure
This technology enables cost-effective future application of morphing structures in aircraft models filling the gap between innovative wing design and reliable repair solutions.
The SUSTAINair technology will allow selective removal of only the damaged flexible skin by debonding its interface and re-bonding of a new skin without effect on the surrounding parts. It is expected that such a repair concept could save 25-50% in repair costs for morphing devices.
Piezoelectric ZnO nanowires for SHM sensors in metallic and polymer parts
This novel technology used on all structural materials (i.e. metals, FRPs) enables the integration of sensors into the structural component and its manufacturing process.
Compared to today’s typical bonding of sensors on a structure’s surface after the actual manufacturing process, the sensor integration should reduce manufacturing costs and increase robustness of the SHM system.
Consequently, maintenance downtimes shall be decreased and lifetime of individual parts shall be increased up to 100% of calculated lifetime due to condition-based maintenance.