In-situ integration and performance verification of large-scale PZT network for composite aerospace structure

Piezoelectric transducer (PZT) based structural health monitoring (SHM) technology has been proved to be effective in increasing safety and reliability of composite aircraft structures. However, the attachment of PZT network to the host structure is considered as a weak link when facing the long term durability requirement of aerospace SHM, which should be overcome for aerospace SHM. In this paper, a surface-mounted co-curing method is creatively proposed to realize in-situ integration of large-scale PZT network and composite structure. By jointly controlling curing temperature and pressure, the proposed method can realize integration of large-scale PZT network and structural surface with high reliability and performance consistency. Compared with the conventional integration methods, the proposed method does not affect the manufacturing process or reduce the mechanical property of structure, and can be easily implemented whenever the host structure is available. To evaluate the effectiveness of the proposed integration method, a large-scale PZT network with an overall dimension of 1100 mm x 600 mm is integrated with a carbon fiber composite panel of wing box. The integration caused influence on functional integrity is first assessed by performing electro-mechanical impedance based theoretical analysis and experimental investigation. Then guided wave signals of the integrated large-scale PZT network are also acquired and analyzed, which proves the good signal repeatability and consistency of the network. At last, the SHM performance of the network is verified by conducting impact damages on the composite panel and performing damage monitoring, experimental results show that accurate monitoring is realized.