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Crack monitoring method based on Cu coating sensor and electrical potential technique for metal structure

Chinese Journal of Aeronautics 2015年第3期28卷 932-938页

作者： Hou Bo He Yuting Cui Ronghong Gao Chao Zhang Teng Aeronautics and Astronautics Engineering College Air Force Engineering University

Abstract Advanced crack monitoring technique is the cornerstone of aircraft structural health monitoring. To achieve realtime crack monitoring of aircraft metal structures in the course of ser vice, a new crack monitoring method is proposed based on Cu coating sensor and electrical poten tial difference principle. Firstly, insulation treatment process was used to prepare a dielectric layer on structural substrate, such as an anodizing layer on 2AI2T4 aluminum alloy substrate, and then a Cu coating crack monitoring sensor was deposited on the structure fatigue critical parts by pulsed bias arc ion plating technology. Secondly, the damage consistency of the Cu coating sensor and 2A12T4 aluminum alloy substrate was investigated by static tensile experiment and fatigue test. The results show that strain values of the coating sensor and the 2A 12T4 aluminum alloy substrate measured by strain gauges are highly coincident in static tensile experiment and the sensor has excel lent fatigue damage consistency with the substrate. Thirdly, the fatigue performance discrepancy between samples with the coating sensor and original samples was investigated. The result shows that there is no obvious negative influence on the fatigue performance of the 2A12T4 aluminum alloy after preparing the Cu coating sensor on its surface. Finally, crack monitoring experiment was carried out with the Cu coating sensor. The experimental results indicate that the sensor is sensitive to crack, and crack origination and propagation can be monitored effectively through analyzing the change of electrical potential values of the coating sensor.

关键词： Aluminum alloy Are ion plating coating sensor Crack detection Electrical potential Fatigue Structural health monitoring

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Structural Surface Crack Monitoring Method Based on Electrical Potential Technique and Modern Surface Technology

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Chinese Journal of Mechanical Engineering 2011年第4期24卷 601-606页

作者： CUI Ronghong HE Yuting YU Zhiming LI Hongpeng SHU Wenjun DU Jinqiang Engineering College Air Force Engineering University Xi＇an 710038 China State Key Laboratory for Corrosion and Protection Institute of Metal Research Chinese Academy of Sciences Shenyang 110016 China 94655 Unit The Chinese People＇s Liberation Army Wuhu 241007 China

Crack monitoring plays a great role in modern structural health monitoring, however, most of the conventional crack inspections have disadvantages in terms of the accuracy, expense, reliability, durability and level of instrumentation required. Thus, development of a simple and reliable crack inspection technique that allows continuous monitoring has been desired. In this paper, electrical potential technique and modern surface technology are employed together to develop a new structural surface crack monitoring method. A special crack monitoring coating sensor based on electrical potential technique was deposited on the hot spot of the structure by modern surface technology. The sensor consists of three layers： the isolated layer, the sensing layer and the protective layer. The isolated layer is prepared by anodic oxidation technology, the sensing layer is made of ion plated copper, and the protective layer is made of silicone. The thickness of each layer is at micrometer magnitude. The electrical conductivity of the sensor is very stable, and the fatigue performance of the specimen with or without coating sensor is nearly unchanged. The crack monitoring experiment result shows that there are two sudden rises of the coating sensor electrical potential values, corresponding to different stages of the crack initiation and propagation. Since the width of the surface coating sensor is only 0.5 mm, this crack monitoring sensor can detect the propagation of cracks less than 0.5 mm long. The method proposed takes the simplicity of electrical potential technique and can monitor surface crack of nearly all kinds of structures precisely. The results of this paper may form the basis of a new crack monitoring system.

关键词： crack monitoring electrical potential technique surface technology coating sensor LY12-CZ aluminum alloy

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