PSI - Issue 75

Available online at www.sciencedirect.com Structural Integrity Procedia (2025) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

ScienceDirect Structural Integrity Procedia (2025) 000 – 000

Procedia Structural Integrity 75 (2025) 200–204

© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper Finite element analysis guided the design to ensure localised stress at notch roots, while experimental validation confirmed consistent failure near 30,000 cycles, indicating 50% of the monitored aluminium alloy’s fatigue life. This passive, scalable solution enables intuitive and cost-effective life estimation for applications in infrastructure and aerospace. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers Keywords: Fatigue Sensor 1. Introduction Fatigue is a progressive and localised structural damage phenomenon that occurs when a material is subjected to cyclic loading [1]. It remains one of the leading causes of failure in safety-critical infrastructure such as bridges, wind turbine blades, aircraft fuselages, and offshore platforms. These systems are routinely exposed to fluctuating mechanical loads throughout their operational lifespan, leading to microstructural deterioration, crack nucleation, and Abstract This study presents a novel class of visually readable polymer-based sensors for fatigue life monitoring of safety-critical structures. The sensors, made from polypropylene with tailored V-shaped notches, are designed to fail at predefined fatigue stages, providing a clear visual indication of structural degradation without requiring power or electronics. Finite element analysis guided the design to ensure localised stress at notch roots, while experimental validation confirmed consistent failure near 30,000 cycles, indicating 50% of the monitored aluminium alloy’s fatigue life. This passive, scalable solution enables intuitive and cost-effective life estimation for applications in infrastructure and aerospace. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers Keywords: Fatigue Sensor 1. Introduction Fatigue is a progressive and localised structural damage phenomenon that occurs when a material is subjected to cyclic loading [1]. It remains one of the leading causes of failure in safety-critical infrastructure such as bridges, wind turbine blades, aircraft fuselages, and offshore platforms. These systems are routinely exposed to fluctuating mechanical loads throughout their operational lifespan, leading to microstructural deterioration, crack nucleation, and Fatigue Design 2025 (FatDes 2025) Visually readable sensors for fatigue life monitoring of safety critical structures Sixin Liu a , Yevgen Gorash b , Mohammad Fotouhi c , Daniel Mulvihill a * a University of Glasgow, Glasgow G12 8QQ, UK b Univeristy of Strathclyde, Glasgow G1 1XL, UK c Technische Universiteit Delft, Mekelweg 5, 2628 CD Delft, Netherland Fatigue Design 2025 (FatDes 2025) Visually readable sensors for fatigue life monitoring of safety critical structures Sixin Liu a , Yevgen Gorash b , Mohammad Fotouhi c , Daniel Mulvihill a * a University of Glasgow, Glasgow G12 8QQ, UK b Univeristy of Strathclyde, Glasgow G1 1XL, UK c Technische Universiteit Delft, Mekelweg 5, 2628 CD Delft, Netherland Abstract This study presents a novel class of visually readable polymer-based sensors for fatigue life monitoring of safety-critical structures. The sensors, made from polypropylene with tailored V-shaped notches, are designed to fail at predefined fatigue stages, providing a clear visual indication of structural degradation without requiring power or electronics.

* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 . E-mail address: author@institute.xxx * Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 . E-mail address: author@institute.xxx

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers 2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2025 organizers

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under the responsibility of Dr Fabien Lefebvre with at least 2 reviewers per paper 10.1016/j.prostr.2025.11.022