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NASA NTRS2005

Distributed sensing of Composite Over-wrapped Pressure Vessels using Fiber-Bragg Gratings

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. These materials offer a wide range of possibilities within the space program. But before they can be reliably incorporated into space flight applications, additional understanding is required in the area of damage tolerance of these materials. Efforts to enhance our understanding of failure modes, mechanical properties, long and short term environmental effects, cyclic damage accumulation and residual strength are needed. Thus we have employed the use of fiber optical sensors which offers an excellent opportunity exploit these materials through monitoring and characterizing their mechanical properties and thus the integrity of structures made from such materials during their life cycle. Use of these optical innovations provides an insight into structures that have not been available in the past, as well as the technology available to provide real time health monitoring throughout its life cycle. The embedded fiber optical sensor shows a clearly detectable sensitivity to changes in the near strain and stress fields of the host structure promoted by mechanical or thermal loading or, in certain conditions, structural damage. The last ten years have seen a large increase in the use of FBG based monitoring systems in a broad range of applications. Fiber Bragg gratings are use to monitor the structural properties of composite pressure vessels. These gratings optically inscribed into the core of a single mode fiber are used as a tool to monitor the stress strain relation in composite structures. The fiber Bragg sensors are both embedded within the composite laminates and bonded to the surface of the vessel with varying orientations with respect to the carbon fiber in the epoxy matrix. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 4400 psi. This is done at both ambient and cryogenic temperatures using water and liquid nitrogen. The recorded response is compared with the response from conventional strain gauge also present on the vessel. Additionally, several vessels were tested that had been damaged to simulate different type of events, such as cut tow, delimitation and impact damage.

Grant, Joseph↗

NASA NTRS2011

Carbon Nanotube-Based Structural Health Monitoring Sensors

Carbon nanotube (CNT)-based sensors for structural health monitoring (SHM) can be embedded in structures of all geometries to monitor conditions both inside and at the surface of the structure to continuously sense changes. These CNTs can be manipulated into specific orientations to create small, powerful, and flexible sensors. One of the sensors is a highly flexible sensor for crack growth detection and strain field mapping that features a very dense and highly ordered array of single-walled CNTs. CNT structural health sensors can be mass-produced, are inexpensive, can be packaged in small sizes (0.5 micron(sup 2)), require less power than electronic or piezoelectric transducers, and produce less waste heat per square centimeter than electronic or piezoelectric transducers. Chemically functionalized lithographic patterns are used to deposit and align the CNTs onto metallic electrodes. This method consistently produces aligned CNTs in the defined locations. Using photo- and electron-beam lithography, simple Cr/Au thin-film circuits are patterned onto oxidized silicon substrates. The samples are then re-patterned with a CNT-attracting, self-assembled monolayer of 3-aminopropyltriethoxysilane (APTES) to delineate the desired CNT locations between electrodes. During the deposition of the solution-suspended single- wall CNTs, the application of an electric field to the metallic contacts causes alignment of the CNTs along the field direction. This innovation is a prime candidate for smart skin technologies with applications ranging from military, to aerospace, to private industry.

Wincheski, Russell↗

DOE OSTI2023

Resilient Hydrogels from the Nanoscale to the Macroscale

Biological systems illustrate how a material composed of fragile molecular components can collectively be highly resilient. While the average protein, cell, or even tissue may not last more than a few weeks, many animals and plants live for more than a century. Continual component regeneration and multiple systems to resist mechanical and chemical damage together make this longetivity possible. This project sought to develop biomimetic methods to enable a specific type of material, a hydrogel, to resist damage across multiple scales using distinct, modular damage protection mechanisms. Because hydrogels share many features with biological tissues, they are an ideal substrate for exploring biomimetic strategies for designing resilience and self-repair. We specifically focused in this study on DNA-crosslinked hydrogels, which contain DNA strands that can serve as material to link it together or to control its current state or properties. We investigated how new tools from dynamic DNA nanotechnology could make it possible to actively recover from damage by continually growing and forming a materials shape, or by identifying damage and directing an adaptive response to that damage involving chemical synthesis to reconstruct a structure. We developed embedded molecular sensors able to detect and strain of the gel before damage occurred and react to counteract damage. We also developed methods to continually create shapes and patterns using chemical processes that will allow those patterns to reform when they are damaged. The ability to design resilient materials capable of self-repair has important implications for materials engineering. Instead of designing a material to withstand the worst stresses it may encounter, we could instead design a material to survive under average conditions, but self-repair or reconfigure to resist impending damage. Resilient, self-repairing hydrogels will also have diverse applications such as sensors or actuators.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Faraday Michelson Interferometers for Signal Demodulation of Fiber-Optic Sensors

We developed an all-fiber-based optical demodulator for the signal interrogation of low-coherence fiber-optic Fabry–Perot interferometric sensors. The optical demodulator consists of a Michelson interferometer implemented by using a 3×3 fiber coupler and two fiber-coupled Faraday reflectors with tunable fiber delay lines. The demodulator's output contains two optical interference signals with a constant phase shift and the output shows no sensitivity to the polarization variation in the light source or fibers. A digital phase recovery algorithm is used to extract the measurand information from the phase-shifted signals at high accuracy, high dynamic range, and high stability. The optical demodulator has been applied to the measurement of high-frequency vibrations and strains using fiber-optic sensors.

47 OTHER INSTRUMENTATION↗

NASA NTRS1991

Active control for vibration suppression in a flexible beam using a modal domain optical fiber sensor

An account is given of the use of a modal-domain (MD) fiber-optic sensor as an active control system component for vibration suppression, whose output is proportional to the integral of the axial strain along the optical fiber. When an MD sensor is attached to, or embedded in, a flexible structure, it senses the strain in the structure along its gage length. On the basis of the present integration of the sensor model into a flexible-structure model, it becomes possible to design a control system with a dynamic compensator which adds damping to the low-order modes of the flexible structure. This modeling procedure has been experimentally validated.

Cox, D. E.↗

NASA NTRS2013

Temperature and Strain Coefficient of Velocity for Langasite SAW Devices

Surface Acoustic Wave sensors on Langasite substrates are being investigated for aerospace applications. Characterization of the Langasite material properties must be performed before sensors can be installed in research vehicles. The coefficients of velocity for both strain and temperature have been determined. These values have also been used to perform temperature compensation of the strain measurements.

Wilson, W. C.↗

DOE OSTI2020

Integrating Radio-Over-Fiber Communication System and BOTDR Sensor System

In this paper, we propose and experimentally demonstrate for the first time, the integration of a radio-over-fiber (RoF) communication system and a Brillouin optical time-domain reflectometry (BOTDR) distributed sensor system using a single optical fiber link. In this proof-of-concept integrated system, the communication system is composed of three modulation formats of quadrature phase-shift keying (QPSK), 16-quadrature amplitude modulation (16-QAM) and 64-QAM, which are modulated onto an orthogonal frequency division multiplexing (OFDM) signal. Whereas, the BOTDR sensor system is used for strain and/or temperature monitoring over the fiber distance with a spatial resolution of 5 m using a 25 km single-mode silica fiber. The error vector magnitude (EVM) is analyzed in three modulation formats in the presence of various BOTDR input pump powers. Using QPSK modulation, optimized 18 dBm sensing and 10 dBm data power, the measured EVM values with and without bandpass filter are 3.5% and 14.5%, respectively. The proposed system demonstrates a low temperature measurement error (±0.49 °C at the end of 25 km) and acceptable EVM values, which were within the 3GPP requirements. The proposed integrated system can be effectively applied for practical applications, which significantly reduces the fiber infrastructure cost by effective usage of a single optical fiber link.

42 ENGINEERING↗

DOE OSTI2024

Multi-Parameter Optical Fiber for Distributed Sensing of Humidity, CH4, CO2, and Corrosion

This work describes the use of the optical fiber sensor (OFS) for successful monitoring of humidity, CH4, and CO2 based on the strain produced along the single-mode fiber (SMF) sensor. This is enabled by absorption of H2O/gases onto the commercially available polyacrylate coated jacketed portion of the fiber resulting in a change in strain. Under equilibrium, a differential microstrain was observed along the jacketed portion of the SMF with N2, CH4, and CO2 at different relative humidity (RH) conditions. The strain response of the SMF under various mixed gas composition and different RH conditions were also measured and made calibration curves accordingly. Linear regression and principal component analysis of the strain datasets provided deconvolution of the impact of strain from H2O, N2, CH4, and CO2. Additionally, modified OFS comprised of the Fe coated fiber section was employed to monitor corrosion based on the increase in backscattered intensity amplitude of the light being passed once corrosion of Fe occurs. Also, corrosion of Fe was studied under soil by installing the fiber in soil with protective measures which would prevent the sensor being mechanically disturbed or broken during installation. The corrosion rates were studied by monitoring the rate at which the intensity of backscattered light amplitude attains a steady state value when complete corrosion of Fe with a specific coating thickness occurs.

Mainali, Badri↗

DOE OSTI2021

Embedded Sensors in Additively Manufactured Silicon Carbide

Silicon carbide (SiC) components are being considered for a wide range of nuclear applications due to their high-temperature strength retention, low neutron absorption, chemical inertness, and dimensional stability under neutron irradiation. However, machining and joining of SiC components have traditionally limited its application to relatively simple geometries. Recent work has demonstrated additive manufacturing of complex, high-purity, crystalline SiC components using a combination of binder jet printing and densification via chemical vapor infiltration (CVI). The process lends itself to embedding of fuel, absorbers, moderators, and sensors at strategic locations within a component. The latter could allow for enhanced in situ performance monitoring of limiting fuel temperatures, self-shielded neutron flux, and potentially spatially distributed strain within complex SiC components if sensors can be successfully embedded during CVI. This work describes (1) methods for embedding sensors; (2) thermodynamic analyses and material compatibility testing for identifying sensors capable of surviving high temperatures and exposure to hydrogen and hydrogen chloride during CVI; and (3) nuclear applications for embedded sensors, including potential failure modes during fabrication and during reactor operation. Molybdenum-sheathed thermocouples were successfully embedded in a complex SiC component, whereas niobium-sheathed high-temperature irradiation-resistant thermocouples started to drift as soon as the reactant gases were introduced and ultimately failed during CVI due to severe constrained expansion, potentially resulting from niobium hydride formation in the low-temperature region of the CVI system. Optical fibers were successfully embedded in SiC, but further work is needed to protect the fragile fiber leads after their protective coatings are removed during CVI.

thermocouples↗

NASA NTRS1986

Research instrumentation for hot section components of turbine engines

Programs to develop research instrumentation for use on hot section components of turbine engines are discussed. These programs can be separated into two categories: one category includes instruments which can measure the environment within the combustor and turbine components, the other includes instruments which measure the response of engine components to the imposed environment. Included in the first category are instruments to measure total heat flux and fluctuating gas temperature. High temperature strain measuring systems, thin film sensors (e.g., turbine blade thermocouples) and a system to view the interior of a combustor during engine operation are programs which comprise the second category. The paper will describe the state of development of these sensors and measuring systems and, in some cases, show examples of measurements made with this instrumentation. The discussion will cover work done at NASA Lewis and at various contractor facilities.

Englund, D. R.↗

NASA NTRS1986

Crash response data system for the controlled impact demonstration (CID) of a full scale transport aircraft

NASA Langley's Crash Response Data System (CRDS) which is designed to acquire aircraft structural and anthropomorphic dummy responses during the full-scale transport CID test is described. Included in the discussion are the system design approach, details on key instrumentation subsystems and operations, overall instrumentation crash performance, and data recovery results. Two autonomous high-environment digital flight instrumentation systems, DAS 1 and DAS 2, were employed to obtain research data from various strain gage, accelerometer, and tensiometric sensors installed in the B-720 test aircraft. The CRDS successfully acquired 343 out of 352 measurements of dynamic crash data.

Calloway, Raymond S.↗

NASA NTRS1990

Research sensors

The LeRC program in research sensors is directed at development of sensors and sensing techniques for research applications on turbine engines and propulsion systems. In general, the sensors are used either to measure to response of an engine component to the imposed environment. Locations of concern are generally within the gas path and, for the most part, are within the hot section of the engine. Since these sensors are used for research testing as opposed to operational use, a sensor lifetime of the order of 50 hr is considered sufficient. The following discussion presents a sample of this work, describing programs to develop a dynamic gas temperature measuring system, total heat flux sensors, a variety of thin-film sensors, and high-temperature strain measuring systems.

Englund, David R.↗

NASA NTRS1991

Titanium honeycomb panel testing

The paper describes the procedures of thermal mechanical tests carried out at the NASA Dryden Flight Research Facility on two tianium honeycomb wing panels bonded using liquid interface diffusion (LID) technique, and presents the results of these tests. The 58.4 cm square panels consisted of two 0.152-cm-thick Ti 6-2-4-2 face sheets LID-bonded to a 1.9-cm-thick honeycomb core, with bearing plates fastened to the perimeter of the upper and the lower panel surfaces. The panels were instrumented with sensors for measuring surface temperature, strain, and deflections to 315 C and 482 C. Thermal stress levels representative of those encountered during aerodynamic heating were produced by heating the upper panel surface and restraining all four edges. After more than 100 thermal cycles from room temperature to 315 C and 50 cycles from room temperature to 482 C, no significant structural degradation was detected in the panels.

Richards, W. L.↗

NASA NTRS1996

Finite Element Simulation of Smart Structures

Finite element equations representing the behavior of piezoelectric materials when bounded to a typical structure and used as sensors and actuators were developed. Emphasis was placed on generating sensor output equations of piezoelectric sensors and responses of a typical structure bonded with piezoelectric sensors and actuators on the basis of finite element formulation. The model can predict not only structural responses due to both mechanical and electrical loading but also electrical potential due to mechanical or thermal effects. The resulted finite element equations were then used for simple control design and performance evaluation. In the control algorithm, voltages coming out from piezoelectric sensors, which are proportional to strains at sensing locations, are taken as input. The voltages applied to the piezoelectric actuators are used as output. The feasibility of integrating control algorithm with the element routine developed herein and FEAP was demonstrated. In particular, optimal independent modal space control was implemented in a software package on the basis of finite element formulation. A rudimentary finite element-control algorithm package was also developed to evaluate the performance of candidate control laws. A few numerical simulations using the software package developed herein were given. The integrated software package will provide a design tool to address issues such as how adaptive smart systems will scale to a full size aircraft, the amount of piezoelectric materials and the powers needed to actuate it for desired performance. It will also provide a viable new structural control design concept for practical applications in large flexible structures such as aerospace vehicles and aircraft.

Cui, Y. Lawrence↗

NASA NTRS2005

High-Temperature, Thin-Film Ceramic Thermocouples Developed

To enable long-duration, more distant human and robotic missions for the Vision for Space Exploration, as well as safer, lighter, quieter, and more fuel efficient vehicles for aeronautics and space transportation, NASA is developing instrumentation and material technologies. The high-temperature capabilities of thin-film ceramic thermocouples are being explored at the NASA Glenn Research Center by the Sensors and Electronics Branch and the Ceramics Branch in partnership with Case Western Reserve University (CWRU). Glenn s Sensors and Electronics Branch is developing thin-film sensors for surface measurement of strain, temperature, heat flux, and surface flow in propulsion system research. Glenn s Ceramics Branch, in conjunction with CWRU, is developing structural and functional ceramic technology for aeropropulsion and space propulsion.

Sayir, Ali↗

NASA NTRS2008

Multifunctional Nanotube Polymer Nanocomposites for Aerospace Applications: Adhesion between SWCNT and Polymer Matrix

Multifunctional structural materials can enable a novel design space for advanced aerospace structures. A promising route to multifunctionality is the use of nanotubes possessing the desired combination of properties to enhance the characteristics of structural polymers. Recent nanotube-polymer nanocomposite studies have revealed that these materials have the potential to provide structural integrity as well as sensing and/or actuation capabilities. Judicious selection or modification of the polymer matrix to promote donor acceptor and/or dispersion interactions can improve adhesion at the interface between the nanotubes and the polymer matrix significantly. The effect of nanotube incorporation on the modulus and toughness of the polymer matrix will be presented. Very small loadings of single wall nanotubes in a polyimide matrix yield an effective sensor material that responds to strain, stress, pressure, and temperature. These materials also exhibit significant actuation in response to applied electric fields. The objective of this work is to demonstrate that physical properties of multifunctional material systems can be tailored for specific applications by controlling nanotube treatment (different types of nanotubes), concentration, and degree of alignment.

Park, Cheol↗

NASA NTRS2009

Method for Real-Time Structure Shape-Sensing

The invention is a method for obtaining the displacement of a flexible structure by using strain measurements obtained by stain sensor,. By obtaining the displacement of structures in this manner, one may construct the deformed shape of the structure and display said deformed shape in real-time, enabling active control of the structure shape if desired.

Ko, William L.↗

NASA NTRS2012

Summary of Activities for Health Monitoring of Composite Overwrapped Pressure Vessels

This new start project (FY12-14) will design and demonstrate the ability of nondestructive evaluation sensors for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. Results will be correlated with other nondestructive evaluation technologies such as Acoustic Emission. The project will build upon a proof of concept study performed at KSC which demonstrated the ability of Magnetic Stress Gages to measure stresses at internal overwraps and upon current acoustic emission research being performed at WSTF; The gages will be produced utilizing Maundering Winding Magnetometer and/or Maundering Winding Magnetometer-array eddy current technology. The proof-of-concept study demonstrated a correlation between the sensor response and pressure or strain. The study also demonstrated the ability of Maundering Winding Magnetometer technology to monitor the stresses in a Composite Overwrapped Pressure Vessel at different orientations and depths. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs.

Russell, Rick↗