A LOW-POWER WIRELESS SENSOR NETWORK FOR MONITORING THE MICROCRACK INITIATIONS IN AEROSPACE COMPOSITES

A low power wireless sensor network was developed to monitor the microcrack events in aerospace composites. The microcracks in the composites mostly result from a stress loading or temperature and/or humidity cycles. Generally, a single microcrack is too small to be detected by conventional techniques such as X-ray or ultrasonic C-scan. The whole developed sensor network is aimed to capture the released acoustic signals by the microcracking events in real time. It comprises of a receiving station as well as a series of sensor nodes. Each sensor node includes two acoustic emission transducers as well as two signal amplification and data acquisition channels. Much of our development effort has been focused on reducing the power consumption of each node and improving the detection reliability for each event. Each sensor node is battery-powered and works in a sleep mode most of time. Once a microcrack is initiated in the composite, the acoustic signal triggers the node and wakes it up. The node will then react in several microseconds and digitize the signal. The digitized data is sent to the station wirelessly. The developed wireless sensor network system has been validated with microscopy of microcracked samples after temperature and humidity cycling and has proved to be an effective tool for microcracking detection. Furthermore, our low power consumption design and sophisticated wireless transmission mechanism enables a system with great potential for field structural health monitoring applications.