Extreme Environment Stress and Strain Sensing System

ABSTRACT: Luna has demonstrated the feasibility of a high speed extreme environment stress and strain measurement system operating at temperatures >900C (1652F) and streaming static and dynamic data at 2.5MHz. During Phase I Luna also demonstrated the system's ability to measure a 26/10Hz AC component on top of a larger 1.2% strain component. The proposed Phase II effort will optimize the data acquisition system and sensors to meet the performance requirements of the Air Force in a delivered prototype. The complete system will consist of multichannel readout electronics, extreme environment transducers, and robust, easily fieldable methods of attachment for both metallic and a composite substrates. Accurate high temperature strain measurements are critical in the development and characterization of modern aerospace materials and verification of vehicle and component performance models. These models are used to determine design parameters and material selection for high speed flight vehicles and component life prediction. Currently there is no suitable technology capable of providing accurate strain data in the presence of both high temperatures and large loads. This Phase II project will develop a prototype system that will be transitioned to the Air Force, commercial aerospace, and automotive industry partners during Phase III. BENEFIT: The proposed system will meet the Air Forces needs for an extreme environment strain measurement system capable of providing accurate static and dynamic data at high speeds. Other agencies such as NASA, DARPA, and the Navy which are performing research on extreme environment materials and systems will also benefit from the technology developed during this program. The system and sensors will enable high temperature, extreme load data to be taken in the presence of high electro-magnetic fields to verify turbine and scramjet engine performance, composite heat shield material characterizations, and airframe dynamic response. These capabilities will also make the system desirable to airframe and engine OEMs to enable performance monitoring and qualification testing which will improve the safety and reliability of commercial transportation. Specifically, Luna has been approached by the automotive industry inquiring about a system with similar needs. In addition to safety improvements through improved material selection and design, the system will enable structural health monitoring and the collection of remaining useful life data which will reduce maintenance overall ownership costs of commercial transports. Luna will work with its commercial partners to complete civilian qualifications and begin marketing the technology for commercial applications during the Phase II&III efforts.