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The future of aerospace structures is highly dependent on the advancement of reliable and high-performance materials, such as composite materials and metals. Innovation in high resolution non-invasive evaluation of these materials is needed for their qualification and monitoring for structural integrity. Aluminum oxide (or α-alumina) nanoparticles present photoluminescent properties that allow stress and damage sensing via photoluminescence piezospectroscopy. This work describes how these nanoparticles are added into a polymer matrix to create functional coatings that monitor the damage of the underlying composite or metallic substrates. Different volume fractions of α-alumina nanoparticles in the piezospectroscopic coatings were studied for determining the sensitivity of the coatings and successful damage detection was demonstrated for an open-hole tension composite substrate as well as 2024 aluminum tensile substrates with a subsurface notch. 

Chromium-doped α-alumina is naturally photo-luminescent with spectral properties that are characterized by R-lines with two distinct peaks known as R1 and R2. When the material is subjected to stress, shifts in the R-lines occur, which is known as the piezospectroscopic (PS) effect. Recent work has shown that improved sensitivity of the technique can be achieved through a configuration of nanoparticles within a polymer matrix, which can be applied to a structure as a stress-sensing coating. This study demonstrates the capability of PS coatings in mechanical tests and investigates the effect of nanoparticle volume fraction on sensing performance. Here, measurements of spectral shifts that capture variation in stress of the coating during mechanical testing and in the region of substrate damage showed that stress contours are more noticeable on a soft laminate than hard laminate. It was found that the 20 % volume fraction PS coating showed the most distinct features of all the coatings tested with the highest signal-to-noise ratio and volume fraction of α-alumina. Post failure assessment of the PS coatings verified that the coatings were intact and peak shifts observed during mechanical testing were due to the stress in the substrate. The results suggest the ability to design and tailor the “sensing” capability of these nanoparticles and correlate the measured stress variations with the presence of stress and damage in underlying structures. This study is relevant to nondestructive evaluation in the aerospace industry, where monitoring signs of damage is of significance for testing of new materials, quality control in manufacturing and inspections during maintenance.