Printed Robust Electronic Sensing Systems (PRESS) for Aircraft Structural Integrity

ABSTRACT: With the increasing age of current military aircraft fleets and current operational and budget environment, there is a need to increase structure reliability and availability while, at the same time, reducing maintenance costs. This is critical especially when some fleets need to be operational beyond its design life. Typical high performance military structure operates under extreme loads that overtime can compromise the integrity of the vehicle. In many cases, highly stressed areas or"hot spots"occur on zones with limited access or not access at all. Conventional inspections of these spots may require time consuming and expensive disassemblies. In order to increase the fleet reliability and availability while reducing operational costs, new technologies are needed to monitor the aircraft structure health. A way to reach this goal is by replacing"conventional"inspections with permanent installed sensors on the structure to assess its structural integrity. In this proposal, QUEST Integrated Inc (Qi2) proposes the use of direct write fuse-like sensors that can be deposit on any type of structure and material. The system is very light, thin and durable. The concept has been based on the sensing, instrumentation, and printed electronics expertise of Qi2. BENEFIT: The fuse-like system presented on this proposal has already demonstrated its functionality at QUEST Integrated Inc. As result, the proposed concept can be advanced quickly for an early implementation on the USAF fleet. Thus, the successful development fuse-like system described within this proposal will reduce maintenance costs while increasing the reliability and readiness of the aircraft hot spot structures. In addition, the ability to install fuse-like sensing network on any type of surface or geometry will allow the use of SHM and embedded sensors at affordable prices on different types of structures. Further, the data provided by the proposed system can be used to manage better the aircraft assess, and to define remedial strategies before the structural damage leads to failure of these structures. This will improve the safety and reliability of the USAF equipment by detecting, monitoring, and managing damage before it reaches a critical state. Other potential users of the technology are in the oil and gas sector.