Damage diagnosis in CFRP/Al7075-T6 aeronautical structures using piezoelectric sensors: characterization and experimental monitoring

Purpose – This study aims to design a damage detection and characterization system (targeting cracks and delamination) for aeronautical composite structures. Design/methodology/approach – This methodology relies on a multidisciplinary approach combining polymer-reinforced/metallic carbon fiber hybrid structures with an integrated network of PZT sensors. It leverages experimental data and employs advanced signal processing and imaging techniques to monitor structural integrity and assess the severity of damage. Findings – Verified experimental results confirm the method's reliability in real-life situations. Research limitations/implications – Research Limits: “The primary challenges involve signal processing complexity due to the hybrid nature of AL7075-T6 and CFRP materials, as well as the potential influence of environmental factors (temperature, pressure) on PZT sensor reliability”. Research Implications: “This work enables a shift toward condition-based maintenance, significantly reducing operational costs while enhancing structural safety and extending the service life of critical aerospace and maritime assets.” Practical implications – This study enables a shift from scheduled to real-time structural monitoring. There is a drastic reduction in inspection time and aircraft downtime. Monitoring the fatigue of hybrid AL/CFRP structures helps to safely extend their service life. The study helps in providing precise diagnostics to optimize repair strategies and minimize human error. Social implications – There is a drastic reduction of structural failure risks through early-stage damage detection. Cost savings in maintenance can lead to more affordable air travel for the general public. The study helps in promoting a circular economy by safely extending the lifespan of complex structures and reducing material waste and also in shifting maintenance roles toward high-tech data analysis and specialized software expertise. Originality/value – The study investigates the complex damage mechanics at the interface of AL7075-T6 and CFRP laminates and helps in combining PZT sensor networks with advanced imaging software for real-time damage characterization. Beyond mere detection, the system assesses “structural criticality, ” providing high-value diagnostic data for maintenance optimization and cost reduction.