Structural Diagnosis of Solid Rocket Motors Using Neural Networks and Embedded Optical Strain Sensors

The main failures that could deteriorate the reliable operation of solid rocket motors (SRMs) and lead to catastrophic events are related to bore cracks and delamination. Current SRMs’ predictive assessment and damage identification practices include time-consuming and cost-demanding destructive inspection techniques. By considering state-of-the-art optical strain sensors based on fiber Bragg gratings, a theoretical study on the use of such sensors embedded in the circumference of the composite propellant grain for damage detection is presented. Deep neural networks were considered for the accurate prediction of the presence and extent of the defects, trained using synthetic datasets derived through finite element analysis method. The evaluation of this combined approach proved highly efficient in discriminating between the healthy and the damaged condition, with an accuracy higher than 98%, and in predicting the extent of the defect with an error of 2.3 mm for the bore crack depth and 1.6° for the delamination angle (for a typical ~406 mm diameter grain) in the worst case of coexistent defects. This work suggests the basis for complete diagnosis of solid rocket motors by overcoming certain integration and performance limitations of currently employed dual bond stress and temperature sensors via the more scalable, safe, sensitive, and robust solution of fiber optic strain sensors.