Materials testing and condition monitoring

The integrity of structural and functional components is particularly crucial in space travel – both during launch and in orbit. Based on extensive material, process and analysis expertise, Fraunhofer IKTS supports and advises on the development of new materials and products, the determination of characteristic values, the clarification of complex failure mechanisms and the achievement of legal and quality standards. In addition to all the necessary standard analysis methods, special, in some cases globally unique, testing options are available.

We also develop high-precision non-destructive testing methods (NDT) and systems for structural health monitoring (SHM) – essential for quality assurance and service life monitoring of aerospace components. The technologies enable the early detection of defects, material fatigue and structural changes – without damaging components.

Material testing under extreme conditions

• High-temperature tests up to 1600°C (air, vacuum)
• Hot gas corrosion testing of materials and components (up to 1500 °C, 40 m/s to 100 m/s, natural gas, H₂ and natural gas/H₂ mixtures, water vapour content in the fuel gas 12 % to 30 %)
• Ceramic high-temperature probe heads for flow measurement technology
• Thermomechanical in-situ analyses, e.g. for additively manufactured or hierarchical structures
• Electrical, thermal and mechanical fatigue tests
• Fractography and failure analysis (e.g. using SEM, TEM, µ and nano X-ray microscopy, in-situ microscopy for structural behavior under load)
• Design and testing of components based on the actual thermal, mechanical and chemical loads during the mission
• Long-term reliability tests to evaluate service life (> 25 years), including media resistance

Simulation, digital technologies and AI
 

• Material characterization for precise material models in the simulation (e.g. to describe ageing or fatigue)
• Augmented reality for real-time visualization of complex 3D data in the inspection of aerospace components
• AI and machine learning for the automated evaluation of NDT data (e.g. for CFRP components)
• Machine learning-based prediction models for failure probabilities
• Digital twins for real-time monitoring and condition assessment of space systems
• DICONDE standards and data fusion (e.g. HF eddy current method) for structured data utilization in space travel

Inline quality control and maintenance inspection based on eddy current and ultrasonic methods (partly according to aerospace standards such as RTCA DO-160)
 

• Inline inspection systems for CFRP fiber composite structures (e.g. wings, tanks, engine cowlings, wound fuselage structures):
  • Texture analysis and damage detection (fiber alignment, gaps, foreign objects)
  • Crack detection, also for concealed and riveted structures
  • Non-contact dielectric analysis to assess heat damage, ageing and polymer degradation
  • Monitoring of conductive coatings
• Robot-based scanners for automated inspection of large components (e.g. aircraft fuselages)
• Flex beam scanners for areas that are difficult to access (e.g. rocket hulls, satellite structures)
• Automated inspection platforms for complex-shaped, non-parallel surfaces (e.g. fan blades, stringers)
• Real-time data acquisition and evaluation for fast decision-making in production
  
   

Structural Health Monitoring
 

• Sensor-based condition monitoring of support structures, tanks or thermal protection systems
• Integration of piezoceramic sensors in structural components for continuous monitoring in orbit (e.g. pressure vessels, aircraft structures)
• Prognostic health management for predictive maintenance and service life monitoring by combining measurement data and digital twins

If standard solutions are not sufficient, Fraunhofer IKTS offers support as a development partner. This begins with feasibility studies to evaluate new testing approaches and ranges from system design and sensor development according to specific requirements to the production and integration of customized sensor and testing systems. The introduction of the systems is also accompanied – including on-site support for testing tasks.

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• Hot gas corrosion tests of materials and components
• Ceramic high-temperature probe heads for flow measurement technology
• Embedded systems for condition monitoring
• Acoustic emission for damage detection on CFRP
• EddyCus^® inline series for production monitoring in the manufacture of CFRP
• 3D free-form scanner for imaging scanning