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This paper addresses the development and real time test validation of an integrated hardware and
software environment that will be able to measure real-time in-situ strain and deformation fields
using a state-of-the-art wireless sensor system to enhance structural durability and damage
tolerance (D&DT), reliability via real-time structural health monitoring (SHM) for sensorized
aerospace structures. The tool will be a vital extension of existing suite of structural health
monitoring (SHM) and diagnostic prognostic system (DPS). The goal of the extended SHM-DPS is
to apply a multi-scale nonlinear physics-based finite element analyses (FEA) to the "as-is"
structural configuration to determine multi-site damage evolution, residual strength, remaining
service life, and future inspection intervals and procedures. Information from a distributed system
of wireless sensors will be used to determine the "as-is" state of the structure versus the
"as-designed" target. The approach enables active monitoring of aerospace structural component
performance and realization of DPS-based conditioned based maintenance. Software enhancements
will incorporate information from a sensor network system that is distributed over an aerospace
structural component. As case study DPS application a realistic composite stiffened panel
representative of fuselage/wing components is selected. Two stiffened panels is manufactured
and instrumented; a) embedded internally between composite layers, and b) surface mounted with
wireless sensors; the second of which with an optimized sensor network. The panels will be tested
in compression following low-velocity impact. The sensor system output will be routed and
integrated with a finite element analysis (FEA) tool to determine the panel's, multi-site damage
locations, and associated failure mechanisms, residual strength, remaining service life, and future
inspection interval. The FEA model utilizes the web/internet based GENOA progressive failure
analysis commercial software suite, durability and damage tolerance (D&DT), and reliability
software capable of evaluating both metallic and advanced composite structural panels under
service loading conditions. The approach utilizes a building block validation strategy, and
real-time structural health monitoring system.
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