Matthew D. Rogge

Shape sensing using multi-core fiber optic cable and parametric curve solutions

The shape of a multi-core optical fiber is calculated by numerically solving a set of Frenet-Serret equations describing the path of the fiber in three dimensions. Included in the Frenet-Serret equations are curvature and bending direction functions derived from distributed fiber Bragg grating strain measurements in each core. The method offers advantages over prior art in that it determines complex three-dimensional fiber shape as a continuous parametric solution rather than an integrated series of discrete planar bends. Results and error analysis of the method using a tri-core optical fiber is presented. Maximum error expressed as a percentage of fiber length was found to be 7.2%.

Characterization of impact damage in composite laminates using guided wavefield imaging and local wavenumber domain analysis.

Delaminations in composite laminates resulting from impact events may be accompanied by minimal indication of damage at the surface. As such, inspections are required to ensure defects are within allowable limits. Conventional ultrasonic scanning techniques have been shown to effectively characterize the size and depth of delaminations but require physical contact with the structure and considerable setup time. Alternatively, a non-contact scanning laser vibrometer may be used to measure guided wave propagation in the laminate structure generated by permanently bonded transducers. A local Fourier domain analysis method is presented for processing guided wavefield data to estimate spatially dependent wavenumber values, which can be used to determine delamination depth. The technique is applied to simulated wavefields and results are analyzed to determine limitations of the technique with regards to determining defect size and depth. Based on simulation results, guidelines for application of the technique are developed. Finally, experimental wavefield data is obtained in quasi-isotropic carbon fiber reinforced polymer (CFRP) laminates with impact damage. The recorded wavefields are analyzed and wavenumber is measured to an accuracy of up to 8.5% in the region of shallow delaminations. These results show the promise of local wavenumber domain analysis to characterize the depth of delamination damage in composite laminates. The technique can find application in automated vehicle health assurance systems with potential for high detection rates and greatly reduced operator effort and setup time.

Guided waves in anisotropic and quasi-isotropic aerospace composites: three-dimensional simulation and experiment.

Three-dimensional (3D) elastic wave simulations can be used to investigate and optimize nondestructive evaluation (NDE) and structural health monitoring (SHM) ultrasonic damage detection techniques for aerospace materials. 3D anisotropic elastodynamic finite integration technique (EFIT) has been implemented for ultrasonic waves in carbon fiber reinforced polymer (CFRP) composite laminates. This paper describes 3D EFIT simulations of guided wave propagation in undamaged and damaged anisotropic and quasi-isotropic composite plates. Comparisons are made between simulations of guided waves in undamaged anisotropic composite plates and both experimental laser Doppler vibrometer (LDV) wavefield data and dispersion curves. Time domain and wavenumber domain comparisons are described. Wave interaction with complex geometry delamination damage is then simulated to investigate how simulation tools incorporating realistic damage geometries can aid in the understanding of wave interaction with CFRP damage. In order to move beyond simplistic assumptions of damage geometry, volumetric delamination data acquired via X-ray microfocus computed tomography is directly incorporated into the simulation. Simulated guided wave interaction with the complex geometry delamination is compared to experimental LDV time domain data and 3D wave interaction with the volumetric damage is discussed.

Multiple-mode Lamb wave scattering simulations using 3D elastodynamic finite integration technique.

We have implemented three-dimensional (3D) elastodynamic finite integration technique (EFIT) simulations to model Lamb wave scattering for two flaw-types in an aircraft-grade aluminum plate, a rounded rectangle flat-bottom hole and a disbond of the same shape. The plate thickness and flaws explored in this work include frequency-thickness regions where several Lamb wave modes exist and sometimes overlap in phase and/or group velocity. For the case of the flat-bottom hole the depth was incrementally increased to explore progressive changes in multiple-mode Lamb wave scattering due to the damage. The flat-bottom hole simulation results have been compared to experimental data and are shown to provide key insight for this well-defined experimental case by explaining unexpected results in experimental waveforms. For the rounded rectangle disbond flaw, which would be difficult to implement experimentally, we found that Lamb wave behavior differed significantly from the flat-bottom hole flaw. Most of the literature in this field is restricted to low frequency-thickness regions due to difficulties in interpreting data when multiple modes exist. We found that benchmarked 3D EFIT simulations can yield an understanding of scattering behavior for these higher frequency-thickness regions and in cases that would be difficult to set up experimentally. Additionally, our results show that 2D simulations would not have been sufficient for modeling the complicated scattering that occurred.

Fastener Failure Detection Using a Surface Acoustic Wave Strain Sensor

Surface acoustic wave (SAW) strain sensors are presented for use in the detection of aircraft fastener failures. SAW sensors have the potential for the development of passive wireless systems. The SAW devices employed four orthogonal frequency coding spread spectrum reflectors in two banks on a high temperature piezoelectric substrate. Three SAW devices were attached to a cantilever panel with removable side stiffeners. Damage in the form of fastener failure was simulated by removal of bolts from the side stiffeners. During testing, three different force conditions were used to simulate static aircraft structural response under loads. The design of the sensor, the panel arrangement and the panel testing results are reported. The results show that the sensors successfully detected single fastener failure at distances up to 655 mm from the failure site under loaded conditions.

Improved sizing of impact damage in composites based on thermographic response

Impact damage in thin carbon fiber reinforced polymer composites often results in a relatively small region of damage at the front surface, with increasing damage near the back surface. Conventional methods for reducing the pulsed thermographic responses of the composite tend to underestimate the size of the back surface damage, since the smaller near surface damage gives the largest thermographic indication. A method is presented for reducing the thermographic data to produce an estimated size for the impact damage that is much closer to the size of the damage estimated from other NDE techniques such as microfocus x-ray computed tomography and pulse echo ultrasonics. Examples of the application of the technique to experimental data acquired on specimens with impact damage are presented. The method is also applied to the results of thermographic simulations to investigate the limitations of the technique.

Vibro-acoustic modulation–based damage identification in a composite skin–stiffener structure:

Vibro-acoustic modulation–based damage identification relies on the modulation of a high-frequency carrier signal by an intenser low-frequency vibration signal due to damage-induced structural nonlinearities. A time domain analysis of the vibro-acoustic modulation phenomena was presented at multiple spatial locations in an impact damaged composite skin–stiffener structure. The instantaneous amplitude and frequency of the carrier velocity response were extracted to analyze the intermodulation effects between the two excitation signals. Increased amplitude modulations at the damaged region revealed the presence, location, and length of the skin–stiffener damage. The damage hardly modulated the frequency of the carrier response. This difference in behavior was attributed to the nonlinear skin–stiffener interaction introduced by the periodic opening and closing of the damage, according to earlier research by authors on the same structure. A parametric study showed that the amplitude and phase of the amplitude modulation are dependent on the selected carrier excitation frequency, and hence the high-frequency wave field that is introduced. This work demonstrates not only the potential but also the complexity of the vibro-acoustic modulation based damage identification approach.

Local guided wavefield analysis for characterization of delaminations in composites

Delaminations in composite laminates resulting from impact events may be accompanied by minimal indication of damage at the surface. As such, inspection techniques are required to ensure defects are within allowable limits. Conventional ultrasonic scanning techniques have been shown to effectively characterize the size and depth of delaminations but require physical contact with the structure. Alternatively, a noncontact scanning laser vibrometer may be used to measure guided wave propagation in the laminate structure. A local Fourier domain analysis method is presented for processing guided wavefield data to estimate spatially-dependent wavenumber values, which can be used to determine delamination depth. The technique is applied to simulated wavefields and results are analyzed to determine limitations of the technique with regards to determining defect size and depth. Finally, experimental wavefield data obtained in quasi-isotropic carbon fiber reinforced polymer (CFRP) laminates with impact damage is a...

Photogrammetric verification of fiber optic shape sensors on flexible aerospace structures

Multi-core fiber (MCF) optic shape sensing offers the possibility of providing in-flight shape measurements of highly flexible aerospace structures and control surfaces for such purposes as gust load alleviation, flutter suppression, general flight control and structural health monitoring. Photogrammetric measurements of surface mounted MCF shape sensing cable can be used to quantify the MCF installation path and verify measurement methods.

SAW sensor for fastener failure detection

The proof of concept for using surface acoustic wave (SAW) strain sensors in the detection of aircraft fastener failures is demonstrated. SAW sensors were investigated because they have the potential for the development of passive wireless systems. The SAW devices employed four orthogonal frequency coding (OFC) spread spectrum reflectors in two banks on a high temperature piezoelectric substrate. Three SAW devices were attached to a cantilever panel with removable side stiffeners. Damage in the form of fastener failure was simulated by removal of bolts from the side stiffeners. During testing, three different force conditions were used to simulate static aircraft structural response under loads. The design of the sensor, the panel arrangement and the panel testing results are reported. The results show that the sensors successfully detected single fastener failure at distances up to 54.6 cm from the failure site under loaded conditions.