Aerospace Composites digitally sensorised

INFINITE developed a sensor system based on the usage of magnetic microwires to be embedded in aerospace composite structural parts and sensed by a portable reader system, in order to monitor manufacturing and structural health throughout the whole life cycle of the component. The reader system produces sensor signals and vast sets of data linked with the specimen in rder to create an as-built digital twin of the structure that will also account for the whole component history since it was manufactured through all maintenance operations performed, until being optimally recycled. The INFINITE project delivered improvements in composite manufacturing and structural health monitoring (SHM) by the development of functional sensorised Non-Crimp fabrics (NCF). These fabrics will provide an efficient real-time monitoring system through a self-sensing fibre by wireless monitoring of the fibre position, orientation, strain-stress and temperature.

In service, the new SHM system provides information about component integrity, performance and safety; therefore informing and improving maintenance operations. The new sensorised NCF will also enable a new repair capability for complex parts. Integration of the magnetic microwires in the fabric opens new possibilities in the design of future functional composites using existing sensoring technologies. This advanced quality monitoring has the potential to deliver a significant impact on cost and safety reliability of composite components, providing a competitive advantage of European manufactures. INFINITE also assessed the effect of sensoring hardware on the current methods for composite recycling, investigating the potential for re-using (other applications, sectors, etc.) both sensors and components to provide useful end of life functionality.