Multi-Sensor Data Fusion for Early Warning of Corrosion-Prone Conditions in Closed Zones of a Medical Rescue Aircraft

Identifying corrosion-prone conditions early is a major maintenance challenge in closed, hard-to-access structural zones. This paper reports an in-service validation of the first monitoring layer of a multi-sensor data fusion approach for early warning of such conditions in selected closed zones of a medical rescue aircraft. The work covers sensor selection, installation in restricted-access compartments, and analysis of data from helicopter operations. Environmental, conductance, and electrochemical channels are combined to identify persistent conditions favorable to long-term corrosion development and to assign warning levels linked to maintenance actions. The thresholds proposed here are empirical screening criteria from the 82-day campaign, not universal damage thresholds or proof of existing corrosion. PZT and eddy-current sensing are planned as follow-up diagnostic layers in the overall architecture. These technologies have been validated separately under laboratory or controlled conditions but were not installed on the flying helicopter during this initial period. Although persistent severe early-warning episodes were detected, they did not coincide with an approved maintenance-access window suitable for additional PZT/EC hardware installation. The present results therefore characterize the corrosion-prone environment and the likelihood of corrosion initiation, not the type, exact location, pit depth, mass loss, or crack initiation of actual damage. Field inspection evidence of corrosion in hidden zones supports the practical relevance of early warning, while full end-to-end validation of localization and damage-growth monitoring remains future work.