Abstract
The eddy current probe, which is flexible, array typed, highly sensitive and capable of quantitative inspection is one practical requirement in nondestructive testing and also a research hotspot. A novel flexible planar eddy current sensor array for the inspection of microcrack presentation in critical parts of airplanes is developed in this paper. Both exciting and sensing coils are etched on polyimide films using a flexible printed circuit board technique, thus conforming the sensor to complex geometric structures. In order to serve the needs of condition-based maintenance (CBM), the proposed sensor array is comprised of 64 elements. Its spatial resolution is only 0.8 mm, and it is not only sensitive to shallow microcracks, but also capable of sizing the length of fatigue cracks. The details and advantages of our sensor design are introduced. The working principal and the crack responses are analyzed by finite element simulation, with which a crack length sizing algorithm is proposed. Experiments based on standard specimens are implemented to verify the validity of our simulation and the efficiency of the crack length sizing algorithm. Experimental results show that the sensor array is sensitive to microcracks, and is capable of crack length sizing with an accuracy within ±0.2 mm.
Highlights
The key components of aircraft such as engine blades are under the long-term effects of cyclic loads and thermal loads, suffering the danger of fatigue failure and the resulting risk of disastrous accidents
Condition-Based Maintenance (CBM) is one kind of maintenance strategy based on device status evaluation, and the status information is obtained by using sensors and external test equipment
Based on the above facts, this paper present the design of a flexible planar eddy current sensor array for quantitative measurement of fatigue crack length in metal components
Summary
The key components of aircraft such as engine blades are under the long-term effects of cyclic loads and thermal loads, suffering the danger of fatigue failure and the resulting risk of disastrous accidents. To ensure safety and prevent accidents, quantitative nondestructive evaluation (QNDE) systems have been proposed and developed against this background. Condition-Based Maintenance (CBM) is one kind of maintenance strategy based on device status evaluation, and the status information is obtained by using sensors and external test equipment. Sometimes the structure must be sifted out, which depends on the size of crack. A reasonable maintenance strategy reduces maintenance costs, and the economic losses due to outage. CBM can ensure the reliability and safety of equipment, reduce the operation and support costs, decrease breakdown maintenance and preventive maintenance tasks, and prevent accidents. QNDE of microdefects is one of the key technologies of CBM, which helps to effectively prevent the generation and spread of various mechanical structural failures and eliminate failure in the embryonic stage
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