FBG-Embedded Sensors for Structural Health Monitoring in Missile Fixed Wings: Enabling Reusability of Solid Rocket Thrusters

The reusability of solid rocket thrusters is a critical objective in advancing the cost-efficiency and sustainability of aerospace systems. Structural Health Monitoring (SHM) is integral to achieving this goal by ensuring integrity and reliability of reusable components. This study proposes the integration of Fiber Bragg Grating (FBG) sensors into the fixed wings of missiles in order to monitor and assess structural health under extreme operational conditions in near real time. FBG sensors, known for their high sensitivity, lightweight, and immunity to electromagnetic interference, are strategically embedded within the composite structure of missile wings to detect strain, deformation, and temperature variations in real-time. A experimental framework is presented, including sensor placement, calibration processes, and data acquisition strategies tailored to the loads and thermal stresses experienced during missile flight. Finite Element Analysis (FEA) simulations validate the sensor placement by predicting stress values for twin digital modelling. The experimental results demonstrate the sensors’ capability to accurately capture strain profiles, providing actionable insights for maintenance and reuse planning.