TECHNOLOGICAL ASPECTS OF CREATING A FIBER-OPTIC NON-DESTRUCTIVE TESTING OF SANDWICH COMPOSITE STRUCTURES

Abstract

The results of research on the formation of the system of built-in non-destructive testing of linings of composite three-layer structures by an optical method using fiber-optic sensors based on fiber Bragg gratings are presented. The features of creating an input/output zone for fiber-optic sensors as applied to three-layer composite structures are studied. Recommendations for ensuring the integrity and optimal functioning of the fiber-optic monitoring system as applied to a real three-layer composite structure are formulated. The following is shown. The process of creating an integrated control system of three-layer composite structures by an optical method using integrated fiber-optic sensors includes a number of operations to form a topology and to ensure the output of fiber-optic sensors from composite claddings in a single technological cycle of manufacturing the structure according to the standard technological process without significantly adjusting it, which is extremely important in relation to serial technologies. When developing the technology of integrating fiber-optic sensors into a three-layer composite structure, it was experimentally shown that from the point of view of survivability and preservation of the efficiency of the embedded control system, it is necessary to fulfill a number of requirements for the placement and output of fiber-optic sensors taking into account the characteristics of manufacturing, machining, and operation designs. Thus, it is advisable to place fiber optic sensors in the casings at least 5 mm from the intended edge of the structure, at least 2 layers from the outer surface of the structure and not less than 5 layers from the honeycomb core. The fiber bend radius should be at least 30 mm to prevent mechanical burst and sharp bending of the signal when it is bending. Fiber optic sensors are recommended to be placed between layers with a reinforcement scheme in the direction of the fiber optic sensor, however placement is also allowed between the fiber sensors and one layer with a different direction of reinforcement, while in order to prevent fractures, computation fiber optic sensors overlap is unacceptable, thus, between crossover fiber-optic sensors must be at least 2 layers of prepreg.