Innovation in Strain Sensing and Damage Detection in Composite Repairs using Printed Gages Navy SBIR FY2009.1 Sol No.: Navy SBIR FY2009.1 Topic No.: N091-025 Topic Title: Innovation in Strain Sensing and Damage Detection in Composite Repairs using Printed Gages Proposal No.: N091-025-0527 Firm: MesoScribe Technologies, Inc. 25 Health Sciences Drive Suite 125 Stony Brook, New York 11790-3350 Contact: Jason Trelewicz Phone: (631) 444-6455 Web Site: www.mesoscribe.com Abstract: Smart composite repair patches, capable of detecting static strain, is a coveted technology for enhancing the fidelity and cost-effectiveness of composite repairs. Direct Write thermal spray (DWTS) is proposed as an innovative approach for fabricating and embedding strain sensors within multifunctional composites. As a novel processing technology platform, DWTS enables low profile, fine feature patterns, such as strain gages, thermocouples, and crack sensors, to be deposited onto composite laminates and embedded within multilayered structures. These unique features render DWTS highly applicable to providing the necessary strain sensing capabilities for integration with composite repairs. The main objectives during the Phase I and Phase I option are to embed strain sensors within composite layups, and demonstrate their functionality and durability through performance testing. Complementary modeling efforts will focus on optimizing sensor integration with composites. Data acquisition and interrogation solutions will also be identified early-on in the technology development process to further drive the Technology Readiness Level beyond a TRL-5 by completion of the Phase II. Benefits: Smart, strain sensing composite repair patches have the potential to significantly enhance the fidelity of composite repair, in turn, easing some of the strict design guidelines and reducing the time required for, and the frequency of costly maintenance inspections. Direct Write thermal spray (DWTS) is an innovative platform technology capable of embedding strain gages within multifunctional composites, thus representing an enabling processing route for smart composite repairs. The ability to monitor static strains in real-time is a vital capability not only for the Navy, but would also have widespread applicability across other branches of the military as well. Over the past few years, MesoScribe has engaged Boeing, Northrop Grumman, and Sikorsky to determine appropriate composite applications and sensing requirements for structural health monitoring and smart repairs. Boeing is extremely interested in DWTS for sensing applications, and has accordingly provided a letter of endorsement with this proposal. Return