The research in this dissertation is motivated by the need for reliable inspection technologies for the detection of bolt loosening in Carbon-Carbon (C-C) Thermal Protection System (TPS) panels on Space Operation Vehicles (SOV) using minimal human intervention.; A concept demonstrator of the Structural Health Monitoring (SHM) system was developed to autonomously detect the degradation of the mechanical integrity of the standoff C-C TPS panels. This system assesses the torque levels of the loosened bolts in the C-C TPS panel, as well as identifies the location of those bolts accordingly. During the course of building the proposed SHM prototype, efforts have been focused primarily on developing a trustworthy diagnostic scheme and a responsive sensor suite. Based on the microcontact conditions and damping phenomena of ultrasonic waves across the bolted joints, an Attenuation-based Diagnostic Method was proposed to assess the fastener integrity by observing the attenuation patterns of the resultant sensor signals. Parametric model studies and prototype testing validated the theoretical explanation of the attenuation-based method.; Once the diagnostic scheme was determined, the implementation of a sensor suite was the next step. A new PZT-embedded sensor washer was developed to enhance remote sensing capability and achieve sufficient sensitivity by guiding diagnostic waves primarily through the inspection areas. The sensor-embedded washers replace the existing washers to constitute the sensor network, as well as to avoid jeopardizing the integrity of the original fastener components. After sensor design evolution and appropriate algorithm development, verification tests were conducted using a shaker and a full-scale oven, which simulated the acoustic and thermal environments during the re-entry process, respectively. The test results revealed that the proposed system successfully identifies the loss of the preload for the bolted joints that were loosened. The sensors were also found to be durable under the cyclic mechanical and thermal loads without major failures.
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