Manufacturing and Preliminary Testing of Nano-Filled Elastomeric Film Cover for Morphing Airfoil

In this paper, a strain-temperature sensor with medium-high stretchability is proposed for aeronautic applications. The elastomer is conceived to be used as a protective cover on a morphing airfoil characterized by high curvatures. The main novelties in design and manufacturing compared to the state of the art are: use of a non-commercial, low-viscosity PDMS crosslinked with TEOS and DBTDL to enable effective graphene dispersion; innovative sensor design featuring an insulating interlayer on the substrate; and presence of micro-voids to enhance adhesion to the substrate. The resistive performance of the nano-filled matrix is preliminarily verified through a basic functionality test during tensile and bending solicitation at room temperature first and then by considering a thermal cycle while imposing a fixed curvature. During tensile tests, the sensor could withstand an imposed elongation of 30%. The bending tests highlighted the capability of the sensors to withstand low curvature radii, lower than 7.5 cm. Then, within the thermal characterization between -20 and +50 °C, a stability of the signal was observed. A basic resistivity (zero strain) of 3.69 MΩ over a sensor 20 mm long (distance between the electrodes), 5 mm wide, and 1 mm thick. All these features make the sensors a good candidate for laboratory prototypes of morphing concepts. Among the most critical applications in the morphing field, one recalls the possibility of integrating many spots of such sensors at the leading-edge zone of a wing, monitoring the strain at extreme curvature points.