Validation of a Piezo Based Integrated Process and SHM System on Hollow Composite Aircraft Part Made by Vacuum Infusion Using a 3D Printed Smart Mold

Abstract

During the last years the authors developed a novel hybrid multi-functional piezo / temperature sensor concept for flow front, cure and structural health monitoring of composite parts thus allowing monitoring of the production and the usage with the same sensor type. Within this paper, the authors present the latest validation results of the developed sensor and monitoring concept on a hollow composite aircraft part. The production of the part was done by vacuum infusion using a smart separable Al mold, made by selective laser melting to enable surface near complex cooling channels and lightweight design. Process parameters such as flow front propagation and degree of cure were successfully monitored during the production of the part. Finally, the ability of the co-cured sensor for passive acoustic emission monitoring for the occurrence of and localization of impacts and the application of guided ultrasonic waves was demonstrated.