CRACKFIRST SENSOR FROM TWI WARNS OF FATIGUE FAILURES

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CRACKFIRST SENSOR FROM TWI WARNS OF FATIGUE FAILURES
07 January 2005 - TWI (The Welding Institute)

TWI has managed the development of a device that measures the amount of fatigue suffered by a welded structure.

TWI, the world centre for joining technology, has managed the development of a device that measures the amount of fatigue suffered by a welded structure. At the heart of the CrackFirst system is a sensor which, when installed on the structure, indicates the portion of the design life that's been consumed and enables engineers to estimate its remaining life.

Unlike a typical strain gauge, which monitors the amount of strain at the point where it is attached to the structure, CrackFirst senses the actual amount of fatigue damage that a structure has suffered. It can be used on any welded steel construction which sees cyclic loading, such as bridges, vehicle chasses, cranes and offshore structures.

The device comprises a steel shim that cracks at a rate that can be related to the fatigue damage being suffered by the structure. Thin film circuitry on the shim is used to measure the crack length, and associated electronics are used to record the sensor's performance over specified time periods.

Designed to give advanced notice of potentially catastrophic fatigue failures, the sensor will help owners avoid the high costs, and health and safety implications, of such failures. It does this by monitoring the percentage of the design fatigue life which has been used up. The warning period is variable, but it can be expected to give months or years of warning of a structure's end of life. The CrackFirstT system will form an important part of many structural Health & Usage Monitoring Systems (HUMS).

The CrackFirst system was developed through the collaboration of TWI Ltd., FMB, Micro Circuit Engineering Ltd., UMIST and Caterpillar Peterlee (A division of Caterpillar (UK) Limited) in a project funded by the DTI's LINK Sensor and Sensor Systems for Industrial Applications Programme.

TWI acted as the project manager for the consortium and contributed to the design, manufacturing, laboratory testing and installation aspects of the project.

John Davenport, Programme Manager at TWI said: 'TWI is very pleased to have been involved with this project. The CrackFirst sensor system will save money for asset managers and reduce the incidence of structural failures. It's an innovative and robust solution to a real world problem.'

TWI is currently involved in the final stages of development and in bringing the system to market. TWI welcomes enquiries from organisations interested in using the CrackFirst sensor system. Please contact Peter Tubby or John Davenport.

TWI's Structural Integrity Group has pioneered many of the approaches that are now widely used around the world for assuring reliability and resistance to fatigue and fracture.

More information can be found at the website: www.twi.co.uk/j32k/unprotected/band_1/sitg_index.html

http://www.twi.co.uk/electronicsandsensors

About: TWI (The Welding Institute)
TWI Ltd, the operating arm of The Welding Institute, is one of the world's foremost independent research and technology organisations. Based at Great Abington near Cambridge since 1946, TWI provides industry with engineering solutions in structures incorporating welding and associated technologies (surfacing, coating, cutting, etc.) through - information; advice and technology transfer; consultancy and project support; contract R&D; training and qualification, personal membership.

It is the only single source of expertise in every aspect of joining technology for engineering materials - metals, plastics, ceramics and composites.

TWI is a non-profit distributing company, limited by guarantee and owned by its Members; it is therefore able to offer independent advice. It is internationally renowned for bringing together multidisciplinary teams to implement established or advanced joining technology or to solve problems arising at any stage - from initial design, materials selection, production and quality assurance, through to service performance and repair.

Over 450 skilled staff are dedicated to helping industry apply all forms of joining technology safely and efficiently. Some 3200 companies and organisations - representing virtually all sectors of manufacturing industry from over 60 countries around the globe - benefit from TWI services.

TWI undertakes contract R & D in confidence for both industry and governments. As a consultant it can offer individual experts or teams able to help solve problems of all kinds related to materials joining. It will send its specialists anywhere in the world at short notice on troubleshooting missions.

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