Embedded Wireless Flexible Sensor for Monitoring Interface Stress of Solid Rocket Motor

Solid rocket motor (SRM) is a reliable and cost-effective aerospace propulsion system, by virtue of its advantages in terms of simple structure, long storage life, low cost, and ease of manufacturing. However, cracks and interfacial delamination may occur at the interface owing to the interface stress resulting from the complex service scenarios throughout the entire life cycle of the SRM. Therefore, it is crucial to monitor the interface stress for health assessment of the SRM. To achieve non-destructive in situ monitoring of interface stress, this paper proposes a novel embedded wireless flexible sensor (EWFS). Through theoretical analysis, the expression of the relationship between the input and output signals of EWFS is formulated. The response patterns of the output signals under different interface stresses are investigated. A prototype of the EWFS comprising the flexible printed circuit board (FPCB) and polydimethylsiloxane (PDMS) is fabricated, along with an interface stress-testing system established for experiments. The experimental results indicate that the EWFS exhibits a sensitivity of 27.2 mV·MPa−1, a linearity error of 1.73%, a maximum hysteresis error of 2.67%, and a stability error of 0.023%.