Analysis of Global Ultrasonic Sensor Data from a Full Scale Wing Panel Test

ABSTRACT. A full scale wing panel fatigue test was undertaken in 2007 as a part of the DARPA Structural Integrity Prognosis System (SIPS) program. Both local and global ultrasonic sensors were installed on the wing panel and data were recorded periodically over a period of about seven weeks. The local ultrasonic sensors interrogated a small number of selected fastener holes, and the global ultrasonic sensors were arranged in a spatially distributed array surrounding an area encompassing multiple fastener holes of interest. The global ultrasonic sensor data is the focus of the work reported here. Waveforms were recorded from all pitch-catch sensor pairs as a function of static load while fatiguing was paused. The time windows over which the waveforms were recorded were long enough to include most of the reverberating energy. Partway through the test simulated defects were temporarily introduced by gluing masses onto the surface of the wing panel, and waveforms were recorded immediately before their attachment and after their removal. The overall fatigue test was terminated while cracks originating from the fastener holes were still relatively small and before they reached the surface of the wing panel. Both detection and localization results are shown for the artificial damage, and the overall repeatability and stability of the signals are analyzed. Also shown is an analysis of how the reverberating signals change as a function of applied load. The fastener hole fatigue cracks were not detected by the global transducer array, which is not surprising given the final sizes of the cracks as determined by later destructive analysis. However, signals were stable throughout the entire fatigue test, and effects of load on the received signals were significant, both in the short-time and long-time signal regimes.