Measuring the crack growth rate of a fatigue crack

using array ultrasonic technology in real-time

Case Study
As part of a number of exploratory research projects, TWI has been trialling the use of array
technology for the real-time monitoring of fatigue crack growth. Establishing the growth rate of
cracks during failure is a key part of assessing the integrity of a structure, as it provides improved
understanding of the behaviour of materials and components under different loading conditions.

Improving the fidelity of structural assessments

In standard test procedures, the crack growth is approximated using NDT methods which require
the test to be stopped periodically in order for measurements to be taken. This projects objective
was to generate a system that essentially collects a real-time ultrasonic video of a crack as it
grows to failure. This then allows the measurement of crack growth rate, ie da/dt, enabling a
more sophisticated assessment of a structures integrity.

Measuring the microscopic

Fatigue cracks are difficult to detect and track for a number of reasons: they often start at
unknown susceptible points or from existing small flaws; they can be very small, ie measured in
micrometres; and their propagation is subject to frequent changes in trajectory. Our key
challenge therefore was to optimise the ultrasonic instrumentation and software to ensure that it
was capable of detecting the crack tip and of tracking and measuring its growth in real-time.

Ascertaining the methods effectiveness

To verify the techniques and methods, a standard fatigue test specimen with a starter notch was
fabricated. The ultrasonic probe was positioned to monitor the notch, and then the test was run in
the fatigue testing machine. The video of the test showing the growth and failure due to a
fatigue crack can be viewed online: http://youtu.be/XADf8MWPNLU
Following the verification trials, full-scale resonance tests were undertaken on pipes with known
susceptible points. Figure 1 shows the pipe setup and the modified system designed to track the
crack in a 2D plane. The ultrasonic techniques being developed include active phased array
methods and real-time full matrix capture methods.
[ Zoom ]

Fig 1: A full-scale resonance test with a modified two-probe system shown below.

Summary
1.

Growth of fatigue cracks can be monitored and tracked in real-time using array ultrasonic
techniques

2.

The data is a plot of the crack size at specific times during the fatigue test and the
gradient of this plot gives the growth rate of the crack at any given time, as given in Figure
2. This result provides insight into the nature of the material and the variable rate of the
crack growth, presenting valuable input to failure models

3.

The video frame rate and the repetition frequency of the instrument can be adapted to
measure growth rate even at the fast fracture period at the end
[ Zoom ]

Fig 2: Graph showing the growth of the fatigue crack measured using the position of the crack tip from the
phased array ultrasonic image

A technology with diverse applications

The monitoring technology is being further developed using a variety of other related methods.
The final system being envisaged is a tool for TWIs resonance testing facility with a two-step
function: (1) detect the onset of a fatigue crack in all possible susceptible areas and (2) monitor
and track its growth to failure.
This system has the potential to be configured for utilisation as a permanently mounted
monitoring system for a range of critical structures and components in industry, including wind
turbine blades, risers used in offshore oil and gas recovery, mooring chains and aircraft.
For more information please contact us.

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