Periodic Reporting for period 1 - INFINITE (Aerospace Composites digitally sensorised from manufacturing to end-of-life)
Reporting period: 2022-06-01 to 2023-11-30
INFINITE aims to develop ferromagnetic MW-based sensors embedded in composite structural parts and analyser for continuous monitoring of manufacturing and structural health throughout the component's life cycle. The wireless monitoring system will generate digital signals and extensive data, creating a digital twin that captures the structure's history since manufacturing, including all maintenance operations.
The project focuses on incorporating advanced sensing technology into aerospace composite components, contributing to transformative digital technologies for the aircraft lifecycle and enhancing competitiveness. The primary goal is to establish a calibrated system that produces valuable data for Structural Health Monitoring (SHM), enabling accurate, cost-effective quality assurance of aerospace composite components. This approach aligns with circular economic strategies, addressing the challenges faced by the European aircraft industry.
To sustain a competitive edge, the incorporation of smart control systems for in-situ monitoring of high-value manufacturing, in-service Maintenance, Repair, and Overhaul (MRO), and End-of-Life (EoL) processes is essential. Digital twins play a crucial role, serving as a digital representation of real assets with intelligent functions to derive maximum benefits, not just as data stores but also as tools for future development.
Composite materials, known for their lightweight and high-performance properties, are extensively used in aircraft manufacturing. The ability to tailor fiber reinforcement placement and incorporate wireless sensors within the composite structure is critical for digital transformation. This aligns with the development of "intelligent structures," encompassing reader, sensor, and smart material development, contributing to achieving environmental targets in the aircraft industry.
The project focuses on incorporating advanced sensing technology into aerospace composite components, contributing to transformative digital technologies for the aircraft lifecycle and enhancing competitiveness. The primary goal is to establish a calibrated system that produces valuable data for Structural Health Monitoring (SHM), enabling accurate, cost-effective quality assurance of aerospace composite components. This approach aligns with circular economic strategies, addressing the challenges faced by the European aircraft industry.
To sustain a competitive edge, the incorporation of smart control systems for in-situ monitoring of high-value manufacturing, in-service Maintenance, Repair, and Overhaul (MRO), and End-of-Life (EoL) processes is essential. Digital twins play a crucial role, serving as a digital representation of real assets with intelligent functions to derive maximum benefits, not just as data stores but also as tools for future development.
Composite materials, known for their lightweight and high-performance properties, are extensively used in aircraft manufacturing. The ability to tailor fiber reinforcement placement and incorporate wireless sensors within the composite structure is critical for digital transformation. This aligns with the development of "intelligent structures," encompassing reader, sensor, and smart material development, contributing to achieving environmental targets in the aircraft industry.
During the initial reporting period (month 1 to month 18) of the project, the requirements and specifications for sensors and measurement systems in various aspects, including manufacturing, Structural Health Monitoring (SHM), end-of-life considerations, and material demonstrations, were defined (WP1).
In the development of the sensor system (WP2), focus was placed on achieving the best magnetic properties of Microwave (MW) in a high carbon fiber environment. Work included manufacturing and measuring the magnetic properties of different ferromagnetic alloys, measuring the signal of embedded MWs in carbon fiber-reinforced epoxy composites, modeling the mechanical and magnetic properties of MWs and composites, and developing a compact reader system. Additionally, activities involved analyzing signal changes in MWs under temperature and stress in composites.
Activities related to Sensorized Materials of Manufacture (MoM), SHM, and repair functionalities included studying Tailored Fiber Placement (TFP) for MW incorporation, exploring the use of multiaxial Non-Crimp Fabric (NCF) manufacturing equipment, and developing automated methods for including MWs in Unidirectional (UD) tapes. Detailed plans for monitoring various manufacturing processes, defining tests, variables to control, and monitoring systems for SHM were outlined. Plans for monitoring critical variables in SHM were also established.
The end-of-life analysis of sensorized composite structures included evaluating their environmental impact using Life Cycle Assessment (LCA) methodology, along with defining initial reuse strategies. Integration and testing of sensorized composites involved evaluating the influence of MWs on composite parts through thermal and mechanical tests.
Lastly, successful management, dissemination, communication, and exploitation activities were carried out during this reporting period.
In the development of the sensor system (WP2), focus was placed on achieving the best magnetic properties of Microwave (MW) in a high carbon fiber environment. Work included manufacturing and measuring the magnetic properties of different ferromagnetic alloys, measuring the signal of embedded MWs in carbon fiber-reinforced epoxy composites, modeling the mechanical and magnetic properties of MWs and composites, and developing a compact reader system. Additionally, activities involved analyzing signal changes in MWs under temperature and stress in composites.
Activities related to Sensorized Materials of Manufacture (MoM), SHM, and repair functionalities included studying Tailored Fiber Placement (TFP) for MW incorporation, exploring the use of multiaxial Non-Crimp Fabric (NCF) manufacturing equipment, and developing automated methods for including MWs in Unidirectional (UD) tapes. Detailed plans for monitoring various manufacturing processes, defining tests, variables to control, and monitoring systems for SHM were outlined. Plans for monitoring critical variables in SHM were also established.
The end-of-life analysis of sensorized composite structures included evaluating their environmental impact using Life Cycle Assessment (LCA) methodology, along with defining initial reuse strategies. Integration and testing of sensorized composites involved evaluating the influence of MWs on composite parts through thermal and mechanical tests.
Lastly, successful management, dissemination, communication, and exploitation activities were carried out during this reporting period.
1. New MWs: Alloys, dimensions, features, magnetic and mechanical behaviour. Taking into account the high carbon fibre content of aerospace composite components, to give rise to a robust signal, a new MW has been manufactured in order to improve its magnetic behaviour due to the composition of the alloy and its diameter. The mechanical behaviour has also been improved, so it is expected that the automated incorporation of the MWs into the carbon fibre fabric will be easier.
2. Configuration of composites. The orientation of the fibres in the layers that make up the composite is very important to the final performance of the solid composite. This orientation of the carbon fibres could be influenced by the presence of the MWs giving rise to new configurations of the stacking of the layers in the preform.
3. Laboratory set-up for measurements. The necessity of rapid detection of the MWs signals in a carbon saturated environment has driven the simplification and improvement of different devices such as coils, amplifiers, and magnetic detectors. The identification of the target parameters of the MW response has made it possible.
4. Simplified portable reader system. The monitorization in the infinite project takes place from the manufacturing process to the end of life, so both sensors and reader systems are necessary in the facilities of the different partners that are involved in the different stages of all value chain. For this reason, a simplified portable reader system has been developed in this period.
5. New strategies for sensor incorporation in the NCFs material. 1) MW on top of two layers of UD carbon fibre tapes positioned at +45° and -45° angles, which are then stitched together. The insertion was made by a new guiding system. 2) DFP tapes with MWs at 0°.
6. Simulations. Simulation models of the stress/strain response of MW.
7. LCA. First approach of the environmental impact of Infinite developments
8. Socio-economic impact. Impact on NCF materials manufacturing industry, on the sensory industry through disruptive wireless sensor technology, on manufacturing and quality control strategies, on composite materials design and certification, on flight efficiency and security and on secondary industries through reuse and recycling.
9. Wider societal implications of the project: i) Securing jobs keeping Europe as the global manufacturing quality leader; ii) Talent acquisition for the European industry, iii) Creation knowledge-intensive jobs in Europe, iv) Implication related to the Environment, resource efficiency and raw materials and v) Significant contribution to the overall safety and efficiency of air travel across Europe.
2. Configuration of composites. The orientation of the fibres in the layers that make up the composite is very important to the final performance of the solid composite. This orientation of the carbon fibres could be influenced by the presence of the MWs giving rise to new configurations of the stacking of the layers in the preform.
3. Laboratory set-up for measurements. The necessity of rapid detection of the MWs signals in a carbon saturated environment has driven the simplification and improvement of different devices such as coils, amplifiers, and magnetic detectors. The identification of the target parameters of the MW response has made it possible.
4. Simplified portable reader system. The monitorization in the infinite project takes place from the manufacturing process to the end of life, so both sensors and reader systems are necessary in the facilities of the different partners that are involved in the different stages of all value chain. For this reason, a simplified portable reader system has been developed in this period.
5. New strategies for sensor incorporation in the NCFs material. 1) MW on top of two layers of UD carbon fibre tapes positioned at +45° and -45° angles, which are then stitched together. The insertion was made by a new guiding system. 2) DFP tapes with MWs at 0°.
6. Simulations. Simulation models of the stress/strain response of MW.
7. LCA. First approach of the environmental impact of Infinite developments
8. Socio-economic impact. Impact on NCF materials manufacturing industry, on the sensory industry through disruptive wireless sensor technology, on manufacturing and quality control strategies, on composite materials design and certification, on flight efficiency and security and on secondary industries through reuse and recycling.
9. Wider societal implications of the project: i) Securing jobs keeping Europe as the global manufacturing quality leader; ii) Talent acquisition for the European industry, iii) Creation knowledge-intensive jobs in Europe, iv) Implication related to the Environment, resource efficiency and raw materials and v) Significant contribution to the overall safety and efficiency of air travel across Europe.