System for in-situ delamination detection in composites

• US 5,814,729 A
• Filed: 09/09/1996
• Issued: 09/29/1998
• Est. Priority Date: 09/09/1996
• Status: Expired due to Term

• Current Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Original Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Inventors: Bicos, Andrew S., Edberg, Donald L., Wu, Shu-Yau
• Primary Examiner(s): Williams, Hezron E.
• Assistant Examiner(s): MOLLER, RICHARD ALAN
• Application Number:
  US08/709,932
• Time in Patent Office: 750 Days
• Field of Search: 73/596, 73/598, 73/599, 73/600, 73/579, 73/763, 73/768, 73/769, 73/775, 73/781, 73/799, 73/800, 73/801, 73/802, 73/582, 73/583, 73/588, 73/602, 364/506, 364/507, 364/508, 364/550, 250/227.14, 250/227.16, 250/227.17, 250/227.18, 356/32, 356/35, 356/35.5
• US Class Current: 73/588
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G01M 5/0066 by exciting or detecting vibration or acceleration vibration testing of structures G01M7/00
• CPC Class Codes: G01N 2291/015 Attenuation, scattering
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 29/045 by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks measuring resonant frequency G01H13/00; measuring strength properties by application of mechanical stress G01N3/00
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/2418 using optoacoustic interaction with the material, e.g. laser radiation, photoacoustics photoacoustic cells G01N21/1702; measuring characteristics of vibrations by using radiation-sensitive means G01H9/00; acousto-optical conversion techniques for short-range imaging G01S15/8965; sound-producing devices using laser bundle G10K15/046
• CPC Class Codes: G01N 29/2475 Embedded probes, i.e. probes incorporated in objects to be inspected

Abstract

In a system for in-situ delamination detection in composites, the invention employs a system which evaluates the mechanical vibration response of composite material structures. The damping characteristics of the composite structure are extracted from the detected wave properties generated by imbedded piezoelectric ceramic actuators and received by imbedded high strain sensitive fiber optic sensors. Such a sensor system is simple to operate for real-time non-destructive strain and displacement monitoring and delamination detection, without the need to remove the tested surface from operation.

During the routine structural integrity monitoring operation, mechanical vibration pulses are launched into the composite from one actuator. The strain signal'"'"'s propagation patterns are measured in real time by the fiber-optic sensors at different grating locations. Different travel times are computed dependent on the location of the receiving gratings.

Propagation of the waves through a delaminated area results in wave modal properties (damping characteristics) which show a difference from those propagating through the delamination-free area. Successive signals from different locations permit computation of the location of the delamination defect.

Claims

1. A sensor system for detecting a defect in laminated composite structures comprising:

at least one mechanical actuator, in operable contact with said laminated composite and adapted for generation of a vibration wave that propagates as a vibration signal along at least one propagation line extending through said laminated composite structure;

at least two delamination sensors, in operable contact with said composite structure, for sensing vibration signals generated by said actuator and propagating along propagation lines defined between said actuator and respective ones of said delamination sensors; and

delamination detection means in operable communication with said delamination sensors for evaluation of said sensed vibration signals that have propagated along propagation lines defined between the actuator and said delamination sensors, wherein said delamination detection means comprises;

means for analyzing the vibration signals propagating along the propagation lines and detected by said respective delamination sensors to determine whether the propagation lines extend through a delamination region in said laminated composite structure;

means for categorizing each of said propagation lines wherein said categorizing step categorizes propagation lines which extend through a delamination region as delamination lines and categorizes propagation lines which do not extend through delamination regions as delamination-free lines; and

means for determining the presence of a delamination region, the location of said delamination region, and boundaries of said delamination region based on the relative positions of said delamination lines and said delamination-free lines.

2. A sensor system as described in claim 1 wherein the mechanical actuator is a piezoelectric actuator.

3. A sensor system as described in claim 1 wherein said mechanical actuator is imbedded in the laminated composite structure.

4. A sensor system as described in claim 1 wherein said analyzing means comprises means for analyzing the vibration signals propagating along the propagation lines to determine whether said vibration signals are dampened such that the amplitude of the vibration signals exceeds a predetermined attenuation limit indicating that said propagation lines extend through a delamination region.

5. A sensor system as described in claim 1 wherein said delamination sensors for sensing vibration signals generated by said actuator are embedded in the laminated composite structure.

6. A sensor system as described in claim 1 wherein said determining means determines the location of said delamination regions by excluding regions in which delamination-free lines extend therethrough.

7. A sensor system as described in claim 1 wherein said determining means determines the boundaries of said delamination region by designating delamination-free lines which are adjacent to delamination lines as boundaries for said delamination region.

8. A sensor system as described in claim 1 wherein said at least one mechanical actuator comprises a plurality of mechanical actuators, wherein said at least two delamination sensors comprise a plurality of delamination sensors, and wherein said means for determining the boundaries of the delamination region constructs a boundary surrounding the delamination region that includes segments of at least three delamination-free lines which are adjacent to at least a portion of a delamination line.

9. A sensor system as described in claim 1 wherein said delamination sensors comprise a fiber optic strand having at least two fiber optic gratings spaced along the length of said fiber optic strand, and wherein said fiber optic gratings sense said vibration signals generated by said mechanical actuator.

10. A sensor system as described in claim 9 wherein said fiber optic gratings are tuned to different frequency ranges and said fiber optic strand provides a modulated sensing signal output containing the sensed signals sensed by each of the fiber optic gratings.

11. A sensor system as described in claim 10 wherein said sensor system further comprises demodulating means connected to said fiber optic strand, and wherein said demodulating means demodulates the modulated sensing signal output by said fiber optic strand into individual sensing signals representing the vibration signals sensed by each of said fiber optic gratings.

12. A sensor system for detecting a defect in laminated composite structures comprising:

at least two mechanical actuators in operable contact with said laminated composite, each mechanical actuator adapted for generation of a vibration wave that propagates as a vibration signal along at least one propagation line extending through said laminated composite structure;

at least one delamination sensor, in operable contact with said composite structure, for sensing said vibration signals generated by each of said actuators and propagating along propagation lines defined between said actuators and said delamination sensor; and

delamination detection means in operable communication with said delamination sensor for evaluation of said sensed vibration signals that have propagated along propagation lines defined between the actuators and said delamination sensor, wherein said delamination detection means comprises;

means for analyzing the vibration signals propagating along the propagation lines and detected by said delamination sensor to determine whether the propagation lines extend through a delamination region in said laminated composite structure;

means for categorizing each of said propagation lines wherein said categorizing step categorizes propagation lines which extend through a delamination region as delamination lines and categorizes propagation lines which do not extend through delamination regions as delamination-free lines; and

means for determining the presence of a delamination region, the location of said delamination region, and boundaries of said delamination region based on the relative positions of said delamination lines and said delamination-free lines.

13. A sensor system as described in claim 12 wherein said actuators generate vibration waves sequentially such that only one vibration wave from only one actuator is propagating as a vibration signal through said laminated composite at a time.

14. A sensor system as described in claim 12 wherein said determining means determines the location of said delamination regions by excluding regions of the laminated composite structure through which delamination-free lines extend.

15. A sensor system as described in claim 12 wherein said determining means determines the boundaries of said delamination region by designating delamination-free lines which are adjacent to delamination lines as boundaries for said delamination region.

16. A sensor system as described in claim 12 wherein said at least two mechanical actuator comprise a plurality of mechanical actuators, wherein said at least one delamination sensor comprises a plurality of delamination sensors, and wherein said means for determining the boundaries of the delamination region constructs a boundary surrounding the delamination region that includes segments of at least three delamination-free lines which are adjacent to at least a portion of a delamination line.

17. A method for detecting defects in laminated composite structures comprising the steps of:

sequentially generating vibration waves at a plurality of predetermined generating locations spaced along said laminated composite structure, wherein said generating step generates vibration waves that propagate as vibration signals along each of a plurality of propagation lines extending through said laminated composite structure;

sensing, at a plurality of sensing locations spaced along said composite structure, vibration signals generated in said generating step that have propagated along propagation lines defined between said plurality of generating locations and said respective plurality of sensing locations;

analyzing the vibration signals propagating along the propagation lines and sensed in said sensing step to determine whether the propagation lines extend through a delamination region in said laminated composite structure;

categorizing each of said propagation lines, wherein said categorizing step categorizes propagation lines which extend through a delamination region as delamination lines and categorizes propagation lines which do not extend through delamination regions as delamination-free lines; and

determining the presence of a delamination region, the location of said delamination region, and boundaries of said delamination region based on the relative positions of said delamination lines and said delamination-free lines.

18. A method as described in claim 17 wherein said determining step comprises the step of determining the location of said delamination regions by excluding regions of the laminated composite structure through which delamination-free lines extend.

19. A method as described in claim 18 wherein said determining step further comprises constructing a boundary surrounding the delamination region that includes segments of at least three delamination-free lines which are adjacent to at least a portion of a delamination line.