Detection of Fatigue Cracks for Concrete Structures by Using Carbon Ink-Based Conductive Skin and Electrical Resistance Tomography

Concrete is among the most widely used structural materials in buildings and bridges all over the world. During their service life, concrete structures may inevitably display cracks due to long-term fatigue loads, leading to the degradation of structural integrity. Thus, it is very important to detect cracks and their growth in concrete structures using an automated structural health monitoring system. In this paper, experimental research on crack detection and imaging of concrete structures by using sensing skin and electrical resistance tomography (ERT) is presented. Carbon ink is screen-printed on the surface of concrete as a conductive material to form sensing skins. With these sensing skins, when cracks occur on or near the surface, it breaks the continuity of the sensing skins and significantly reduces conductivity in cracking areas. Then, after exciting small currents in sensing skins and measuring related voltage data, an inverse analysis based on total variation (TV) regularization is adopted to reconstruct tomographic images showing conductivity changes in sensing skins, to detect the occurrence and growth of cracks. The effectiveness of conductive sensing skins and our related crack detection method is validated in experimental studies on a concrete beam subjected to fatigue tests.

Stretchable Carbon and Silver Inks for Wearable Applications

For wearable electronic devices to be fully integrated into garments, without restricting or impeding movement, requires flexible and stretchable inks and coatings, which must have consistent performance and recover from mechanical strain. Combining Carbon Black (CB) and ammonia plasma functionalized Graphite Nanoplatelets (GNPs) in a Thermoplastic Polyurethane (TPU) resin created a conductive ink that could stretch to substrate failure (>300% nominal strain) and cyclic strains of up to 100% while maintaining an electrical network. This highly stretchable, conductive screen-printable ink was developed using relatively low-cost carbon materials and scalable processes making it a candidate for future wearable developments. The electromechanical performance of the carbon ink for wearable technology is compared to a screen-printable silver as a control. After initial plastic deformation and the alignment of the nano carbons in the matrix, the electrical performance was consistent under cycling to 100% nominal strain. Although the GNP flakes are pulled further apart a consistent, but less conductive path remains through the CB/TPU matrix. In contrast to the nano carbon ink, a more conductive ink made using silver flakes lost conductivity at 166% nominal strain falling short of the substrate failure strain. This was attributed to the failure of direct contact between the silver flakes.

A Low-Cost Strain Gauge Displacement Sensor Fabricated via Shadow Mask Printing

This work presents a cost-effective shadow mask printing approach to fabricate flexible sensors. The liquid-state sensing material can be directly brushed on a flexible substrate through a shadow mask. The ink leakage issue which often occurs in printed electronics is addressed with a custom taping scheme. A simple thermal compression bonding approach is also proposed to package the functional area of the sensor. To verify the feasibility and robustness of the proposed fabrication approach, a prototyped strain gauge displacement sensor is fabricated using carbon ink as the sensing material and a flexible polyimide (PI) film as the substrate. Once the substrate is deformed, cracks in the solidified ink layer can cause an increased resistance in the conductive path, thus achieving function of stable displacement/strain sensing. As a demonstration for displacement sensing application, this sensor is evaluated by studying its real-time resistance response under both static and dynamic mechanical loading. The fabricated sensor shows a comparable performance (with a gauge factor of ~17.6) to those fabricated using costly lithography or inkjet printing schemes, while with a significantly lower production cost.