Concentric Ring Film Sensor Array and Its Experimental Research on Crack Monitoring for Aircraft Metallic Structure

Abstract

Abstract: Fatigue damage of aero metal components causes serious threat to flight security. According to the requirement of metallic structural fatigue crack monitoring in real time, a concentric ring film sensor array integrated with structural substrate and corresponding monitoring method are proposed. The concentric ring film sensor array is designed and optimized. Surface treatment technology is introduced for surface insulation treatment of the substrate, and then pulsed bias arc ion plating technology is introduced to deposit concentric ring film sensor array. Fatigue damage monitoring experiment of structural simulating sample is carried out with the concentric ring film sensor array. Monitoring experimental result shows that the sensor is very sensitive to structural crack, monitoring signal of voltage increased rapidly when structural cracking begin to appear or crack front expands into monitoring area of the corresponding film sensor, and monitoring signal of voltage experiences a step rise and failure of the monitoring channel occurs when crack front expands out of the monitoring area of the corresponding film sensor. Taking variation characteristics of monitoring data as judgment criterions of structural crack initiation, crack front’s entering corresponding monitoring area, crack front’s crossing corresponding monitoring area, concentric ring film sensor array can realize quantitative monitoring of fatigue crack, and monitoring precision is 1 mm. Besides, the degree of structural fatigue accumulation damage can also be analyzed qualitatively through monitoring data variation of inner ring film sensor.

Key words: arc ion plating, crack, electrical potential difference method, film sensor, structural health monitoring

HOU Bo, CUI Ronghong, HE Yuting, GAO Chao, ZHANG Teng. Concentric Ring Film Sensor Array and Its Experimental Research on Crack Monitoring for Aircraft Metallic Structure[J]. Journal of Mechanical Engineering, 2015, 51(24): 9-14.

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