Strain characterization of embedded aerospace smart materials using shearography

The development of smart materials for embedding in aerospace composites provides enhanced functionality for future aircraft structures. Critical flight conditions like icing of the leading edges can affect the aircraft functionality and controllability. Hence, anti-icing and de-icing capabilities are used. In case of leading edges made of fibre metal laminates heater elements can be embedded between composite layers. However this local heating causes strains and stresses in the structure due to the different thermal expansion coefficients of the different laminated materials. In order to characterize the structural behaviour during thermal loading full-field strain and shape measurement can be used. In this research, a shearography instrument with three spatially-distributed shearing cameras is used to measure surface displacement gradients which give a quantitative estimation of the in-and out-of-plane surface strain components. For the experimental part, two GLARE (Glass Laminate Aluminum Reinforced Epoxy) specimens with six different embedded copper heater elements were manufactured: two copper mesh shapes (straight and S-shape), three connection techniques (soldered, spot welded and overlapped) and one straight heater element with delaminations. The surface strain behaviour of the specimens due to thermal loading was measured and analysed. The comparison of the connection techniques of heater element parts showed that the overlapped connection has the smallest effect on the surface strain distribution. Furthermore, the possibility of defect detection and defect depth characterisation close to the heater elements was also investigated.