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Home Sensors Multilayer Film Sensor for Damage Diagnostics

Multilayer Film Sensor for Damage Diagnostics


The new innovative approach to damage diagnostics within the production and maintenance/servicing procedures in industry is proposed. It is based on the real-time multiscale monitoring of the smart-designed multilayer film sensors (SMFS) of fatigue damage with the standard electrical input/output interfaces which can be connected to the embedded and on-board computers.

SMFS is a multilayer (~ 0.2-0.4 mm) structure which could be rigidly attached (glued, welded or sputtered) to the underlying engineering component with complex geometry. The first lowest layer is a highly sensitive soft single crystalline film that undergoes the permanent evolution due to external deformation influence from the underlying engineering component. The second layer is assumed to be made from different polymers with physical characteristics (electrical resistance, inductance, capacity, etc.) which are highly sensitive to form changes. The third layer is a multiscale grid of contacts for data acquisition that creates the standard interface for plugging to the embedded or onboard computer systems.

SMFS supply information about the actual unpredictable deformation damage, actual fatigue life, strain localization places, damage spreading, etc.

Innovative Aspect and Main Advantages

Current techniques can provide the measurement of a single fatigue feature only, such as crack growth or instant strain, while the technology discussed herein is designed to measure a whole range of fatigue parameters in the monitored area.

The expected benefits of SMFS could be summarized as followed:

  • to reduce frequency of inspection periods of engineering constructions;
  • to provide real-time data therefore giving greater safety assurance;
  • to enable further reduction of conservatism in design because of ‘real-time’ safety net;
  • to offer new design approaches for weight and maintenance optimization.

Areas of Application

SMFS is suitable for diagnostics of the constructive elements which failure could lead to catastrophe in the following engineering fields: aerospace, automotive industry; high-pressure reservoir and reactor materials, joints, welds to extend the integrity and lifetime of installed pipelines and their various components; bridge building, civil engineering, etc., especially under the real random spectra of loading conditions.

The immediate aerospace application is in the measurement of the actual accumulated fatigue damage of areas of high stress concentrations. Potential areas may be at the aft/centre and front/centre fuselage junctions, as well as centre-fuselage/wing junctions. Further fuselage frames and some areas on the lower wing skin may be sensitive to fatigue loading and subsequently could benefit from such tool.

Fig. 1 Laboratory Virtual Reality Model: standard GSM phone with camera
used for SMFS scanning, data transmitting by GPRS protocol to integral processing
of the actual damage of the whole engineering construction

Stage of Development

Development phase - laboratory tested, feasibility study.

Contact Details

G.V. Kurdyumov Institute for Metal Physics, NAS of Ukraine
Contact person: Dr. Yuri Gordienko
Address: 36, Vernadsky Str, 03680, Kyiv, Ukraine
Tel.: (+38 044) 424 9556
Mob.: (+38 066) 146 9714
Fax: (+38 044) 424 2561
E-mail: This e-mail address is being protected from spambots. You need JavaScript enabled to view it

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