Challenges of an Industrialized Acousto-Ultrasonic Sensor System Installation on Primary Aircraft Structure

Abstract : At laboratory level, secondary bonding of Acousto-Ultrasonic sensor systems is well established and has proven its reliability in applications from coupon level up to flight test installations. However, the applied sensor secondary bonding is a manual process with high amount of required auxiliaries and tools and is hence associated with high costs. In transition from sensor installation under laboratory conditions to the installation of large-scale sensor networks within an aircraft serial production process, costs associated with sensor installation become a decisive factor. By developing the sensor co-bonding approach, an installation method for fiber reinforced plastics host structures is created which requires significantly less work, auxiliaries and tools. Yet, while a considerable reduction of installation cost seems achievable, the application of sensor co-bonding as an industrialized process for aircraft primary structure is clearly more challenging. The present paper outlines specific advantages of sensor co-bonding and discusses challenges ahead on the way towards an industrialized sensor installation on aircraft primary structures.