A real-time active smart patch system for monitoring the integrity of bonded repair on an aircraft structure

There currently exists a need to develop a cost-effective, in-service structural health monitoring (SHM) system for determining the initial quality of a bonded repair and assessing the long-term durability of the bonded repair on an aircraft structure. In this paper, a real-time active smart patch system (SPS) based on SMART layer technology is introduced for monitoring the integrity of bonded repairs. First, an overview of the SPS is given for typical metal and composite repairs. To illustrate the capability of the SPS, three applications are presented: (1) monitoring of the cure progress of the bonded repair adhesive, (2) detection of the initial artificial disbond between the composite patch and the metal structure, and (3) monitoring of damage in and around a bonded repair during fatigue cycling. The results show that, through the use of a real-time active SPS approach of using sensors placed in, on or around the repair, the initial quality and long-term durability of the repair can be evaluated and monitored.