The Fatigue Growth Sensor (FGS) System: Background, Improvements, Steps Forward

Prepared By Non Invasive Technologies, Inc Los Angeles, CA 90049 310-384-2428

FGS System Background

The FGS system is a nondestructive fatigue crack inspection system.

FGS System includes: two electrolyte-filled sensors, a Potentiostat Data Link (PDL), and special software.

The FGS System - Background

Developed in the early 1990s, in part through sponsorship by the US Air Force.

Internal and external verification (Rockwell Scientific); Validation studies conducted in both laboratory and field (including the AAR FRA TTCI facility).
Can detect cracks as small as 0.001 in. in lab. Part of SIPS program. Detects crack growth activity and crack growth precursors. Adds value to all inspection and predictive maintenance programs, as well as provides better information for models.

Similar to an EKG
Like an EKG:
EKG (electrocardiogram) - a test that records the electrical activity of the heart, shows abnormal rhythms.

FGS The Fatigue Growth Sensor

Constant voltage applied between structure and electrode Current response due to mechanical loading -> FGS signal A crack changes how the current flows

Normal EKG

Abnormal EKG

Normal FGS

Abnormal FGS

Fundamentals of FGS
Uses passivation of the metallic surface to measure fatigue damage:
Sensor polarizes area, creates passive film. In growing cracks, cyclic loading breaks down passive layer. Micro-plasticity at crack tip changes amount of exposed metal. As new metal is exposed, new, additional passive forms which signal. film changes FGS

The Differential FGS Set-up

An FGS sensor array is applied to an area of interest and crack detection occurs under or around the sensor.
The Crack Measurement Sensor (CM) is placed over the tip of the crack. The Reference Sensor (R) is placed in the same stress field, but where there is no crack.

The FGS System Hardware

FGS Sensors
Measurement & Reference Customizable size, shape, geometry

PDL (Potentiostat Data Link).

Precisely controls FGS sensor array voltage Measures the current flow for the two sensors (indicator of crack condition) Controls Data Acquisition Rate Controls Data Collection Times

Stores Data Locally

Wireless and battery powered

Typical Bridge Installation

Surface Preparation

Sensor Installation

Hardware Installation

Wireless Access Point

Data Acquisition

Example Installations

Basics of Data Interpretation

Differential FGS used.
Comparison of CM and R Sensors.

Ratio of the CM sensor and R sensor data used as first decision metric -> Energy Ratio.
Special software uses specially designed algorithm to determine growth activity. Possible Output No Growth Microplasticity (Future Initiation) Active Growth

The FGS System - Software

Frequency content and magnitude differences indicate crack condition. Algorithm preliminarily indicates crack activity status. Results = Energy Ratio
No growth<1.5 1.5<Potential growth<1.9 1.9<Active crack growth

Predictive Capabilities:
Threshold Lab Verifications
Controlled environment

Precise measurements
Dynamic Input Theoretical comparisons

Experimental Setup

Crack

14

Fatigue Data

15

Crack Growth Data

16

Testing Procedure
Specimen Polished and Pre-cracked.

Crack length measured on polished surface.

Loads are determined for DK below and above DKth threshold. Tests are conducted at each of the various DK for 10 minutes and FGS data is collected. Post data collection samples are fractured and the crack length measured.

Fracture Surface

FGS and Threshold Bridge Loading

19

FGS and Threshold

20

Energy Ratio
Energy Ratio = Ratio of Areas Under Crack Measurement and Reference Measurement Curves

Energy Ratio = 1.16 DK = 2.54 ksi in

Energy Ratio = 2.4 DK = 17.25 ksi in

22

Improving the Standard of Care

Federal Highway Administration Reliability of Visual Inspection Study of 49 State DOT bridge inspectors.
Multiple fatigue crack indications at multiple locations All at obviously fatigue sensitive locations

Inspectors correctly identified the crack indications less than 10% of the time.
That means 90 out of every 100 fatigue cracks are missed by conventional methods Also repairs are being made 4 out of 5 times at areas which do not require it (80% false positives).

Frequency Domain Active Sample Output Typical

Energy Ratio ER=1.3 Location 1a: No Significant Activity,= 3.1

Conclusions
Obtain additional, more useful, more accurate information for decisions. Almost immediate repair verification. Predictive information available for fatigue critical locations. Integrate with FASTRAN II.
Find hotspots in all structures
Bridges, aircraft, offshore platforms, ships, shipping cranes

Next Steps for Product Improvement

Shift Focus to 7075 AL.
Polarizing voltage
Threshold correlation curves

Crack growth rate. Localized excitation method. Develop fracture mechanics methodology to transfer FGS into FASTRAN based code. Long term sensor/electrolyte change.

Approximate Inspection Costs

Costs are based on number of areas to be inspected. Inspection crew can cover up to ten crack locations in one shift, depending on ease of access. For a simple two span bridge cost will be approximately US$15,000.