Innovation in Strain Sensing and Damage Detection in Composite Repairs using Printed Gages

Smart composite repair patches, capable of detecting static strain, is a coveted technology for enhancing the fidelity and cost-effectiveness of composite repairs. Direct Write thermal spray (DWTS) is proposed as an innovative approach for fabricating and embedding strain sensors within multifunctional composites. As a novel processing technology platform, DWTS enables low profile, fine feature patterns, such as strain gages, thermocouples, and crack sensors, to be deposited onto composite laminates and embedded within multilayered structures. These unique features render DWTS highly applicable to providing the necessary strain sensing capabilities for integration with composite repairs. The main objectives during the Phase I and Phase I option are to embed strain sensors within composite layups, and demonstrate their functionality and durability through performance testing. Complementary modeling efforts will focus on optimizing sensor integration with composites. Data acquisition and interrogation solutions will also be identified early-on in the technology development process to further drive the Technology Readiness Level beyond a TRL-5 by completion of the Phase II.