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The reliability of nanocomposite conductive inks under cyclic loading is the key to designing robust flexible electronics. Although resistance increases with cycling and models exist, the exact degradation mechanism is not well understood and is critical for developing inks. This study links cracking behavior to changes in electrical resistance by performing in situ cyclic stretch experiments in scanning electron microscopy (SEM) with synchronized resistance measurements. Two screen-printed conductive inks, PE874 and 5025, on thermoplastic polyurethane (TPU) and polyimide (PI) substrates, respectively, were tested using the in situ technique. The obtained SEM images were analyzed with digital image correlation (DIC) to map the strain across cycles. The strain maps show that fatigue damage mainly occurred within the cracks formed during the initial monotonic stretch. There was no delamination at the ink–substrate interface or crack extension along the surface with cycling. Instead, fatigue damage resulted from a combination of crack widening and local shearing within the existing cracks. Crack depth varied based on the ink and substrate properties. The cracks in the 5025 ink on the PI substrate were only partially through the ink thickness, while fully through-thickness cracks were more prevalent in the PE874 ink on the TPU substrate. The 5025 ink showed a faster resistance increase with cycling than the PE874 ink because fatigue damage affected more bridging ink material for partial through-thickness cracks. Higher strain amplitudes caused greater crack widening and shearing and therefore faster resistance increase per cycle.
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This content will become publicly available on October 1, 2026
Digital Shearography for NDE of Crack Classification in Composite Materials
This paper presents a relevant and timely study on the application of thermal loaded digital shearography for crack classification in glass fiber reinforced plastic (GFRP) structures, particularly air-cooled condenser (ACC) fan blades. A thermal loaded digital shearography system was applied to measure strain concentration caused by the cracks at different fatigue cycles. A thermomechanical model was introduced to estimate the heating temperature and the time to ensure heat can reach to the desired depth and that both shallow and deep cracks can be detected. In order to correlate the information of strain concentration in the shearograms to the different stages of cracks, fatigue testing with dynamic three-point bending was conducted. The fatigue tests demonstrated how the strain concentration evolved in the shearograms, while the crack developed from the early (no noticeable strain concentration), to the middle (strain concentration is forming), to the late stage (significant strain concentration is found). The relationships between the degrees of strain concentration in the shearograms and the different stages of cracks can be obtained from testing of the artificial cracks. Using the rules and experimental results obtained from artificial samples, digital shearography was applied to classify the crack stages in parts of ACC fan blades from industry. The combination of artificial crack testing, fatigue loading experiments, and validation with CT scans demonstrates a comprehensive approach and provides potential guidance for industry to determine criticality and maintenance criteria.
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- Award ID(s):
- 2052658
- PAR ID:
- 10692515
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Applied Sciences
- Volume:
- 15
- Issue:
- 19
- ISSN:
- 2076-3417
- Page Range / eLocation ID:
- 10317
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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