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Aerospace systems are expected to remain in service well beyond their designed life. Consequently, maintenance is an important issue. A novel method of implementing artificial neural networks and acoustic emission sensors to form a structural health monitoring (SHM) system for aerospace inspection routines was the focus of this research. Simple structural elements, consisting of flat aluminum plates of AL 2024-T3, were subjected to increasing static tensile loading. As the loading increased, designed cracks extended in length, releasing strain waves in the process. Strain wave signals, measured by acoustic emission sensors, were further analyzed in post-processing by artificial neural networks (ANN). Several experiments were performed to determine the severity and location of the crack extensions in the structure.

ANNs were trained on a portion of the data acquired by the sensors and the ANNs were then validated with the remaining data. The combination of a system of acoustic emission sensors, and an ANN could determine crack extension accurately. The difference between predicted and actual crack extensions was determined to be between 0.004 in. And 0.015 in. With 95% confidence.

These ANNs, coupled with acoustic emission sensors, showed promise for the creation of an SHM system for aerospace systems. Introduction Even though the current method of inspecting aircraft, consisting of ground inspections for damage after a set number of flight hours, works well from an aircraft safety point of view, it can be improved upon for greater productivity. An in-flight structural health monitoring (SHM) system would allow for better use of components, as specific lifetimes could be determined. Maintenance cost might be reduced since an SHM system could be embedded into the aircraft structure, thereby reducing or eliminating the need to remove the aircraft from service to scan for damage during the ground inspection. Ground inspections of aircraft, even using simple nondestructive testing techniques, generally require the aircraft be pulled from service so that its components can be inspected for damage. Structural components are replaced if sufficient damage is found.

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Research is underway to develop a structural health monitoring (SHM) system as a means to improve current maintenance procedures. This system would consist of an array of sensors and associated analysis which would scan for damage in-flight and perform real-time damage analysis of an aircraft's structure. If damage is recognized long before failure occurs, then a damage tolerance and prognostic assessment could be implemented, allowing for a determination of the remaining life of components. This paper contains the results of an investigation of the abilities of a passive ultrasonic scanning system, called an acoustic emission system.

The focus of this research effort was on the development of a quick, accurate and precise method of automating a structural health monitoring (SHM) system to optimize the analysis capabilities of an acoustic emission system in order to locate and assess damage in a structural component. The basic acoustic emission system was augmented with an artificial neural network analysis to provide near real-time analysis of acoustic emission data measured from aircraft structural components, during routine service operations. Acoustic Emission As a crack propagates in a material, molecular bonds are broken, releasing small amounts of energy. The energy released spreads throughout the surrounding material in the form of strain waves.