UltraLife · Development of a physics-informed data-driven remaining useful life prediction framework for CFRP composite structures using ultrasonic guided waves

The EU is a world leader in the aerospace industry, and the global reusable launch vehicle (RLV) market is projected to surge from USD 1.94 billion in 2023 to USD 5.41 billion by 2030, facilitated by its eco-friendliness, cost-effectiveness, and time-saving rebuild process enabled by rocket stage recovery. Due to their high strength-to-weight ratio, carbon fiber-reinforced polymer (CFRP) composites are prevalent in RLV structures, such as fuel tanks, thermal protection, and engine structures. Still, their inspection is complicated and time-consuming, impacting downtime and safety. Therefore, real-time remaining useful life (RUL) prediction is crucial for predictive maintenance in the era of Industry 4.0. Onboard structural health monitoring (SHM) systems can mitigate downtime but face challenges in RUL prediction due to fatigue damage complexities. Ultrasonic guided waves (UGW) technology shows promise in detecting and quantifying fatigue damage in CFRP, yet complex fatigue mechanisms and defects hinder accurate analysis. Investigating the correlation between UGW responses and CFRP fatigue damage for further RUL prediction could revolutionize design and maintenance, guiding against overdesign and facilitating informed maintenance decision-makings. Therefore, analyzing the nonlinear mapping relationship between UGW signals and the RUL of CFRP composites is a fundamental problem that remains unresolved. UltraLife will bring together a Fellow with expertise in predictive maintenance with the host institution carrying leading academic know-how in UGW interactive modeling in order to develop the next generation of robust SHM systems for RUL prediction of composite structures in the ever-growing aerospace composites sector. UltraLife will facilitate predictive maintenance by establishing a physics-informed data-driven RUL prediction framework enabling online monitoring of CFRP structural health state and boost Europe to the forefront of the maintenance market.