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The present paper investigates monitoring of fatigue cracks of a metal structure using an eddy current micro sensor. Fatigue cracks tend to occur at bolt-jointed structures on an aircraft. In order to detect the damage quantitatively, a kind of change-prone micro eddy current sensor is designed and fabricated with flexible printed circuit board (FPCB) technology. A forward semi-analytical model is built by extracting a material’s conductivity as the damage feature parameter, and characteristics analysis is conducted based on the model. The research focuses on setting up and utilizing the eddy current fields to analyze interaction of adjoining coils when the damage occurs, and investigating optimization on the working parameters of the sensor. In the experimental section, several common connection structures are applied to explore the sensor’s monitoring ability both in air and in a corrosive environment. The result shows that the optimal working frequency is about 1 MHz. The eddy current micro sensor is capable of monitoring the crack growth with an accuracy of 1 mm, the average error being 4.6 % compared to fracture analysis. The sensor keeps high resolution of damage in aqueous corrosion. Due to the fretting fatigue, wear appears on the polyimide foil, leading to the decreases of the monitoring signal.

Monitoring fatigue cracks of a metal structure using an eddy current sensor