Tag Archives: thermoelastic stress analysis

Finding DIMES

A couple of weeks ago I wrote about the ‘INSTRUCTIVE final reckoning’ (see post on January 9th).  INSTRUCTIVE was an EU project, which ended on December 31st, 2018  in which we demonstrated that infra-red cameras could be used to monitor the initiation and propagation of cracks in aircraft structures (see Middleton et al, 2019).  Now, we have seamlessly moved on to a new EU project, called DIMES (Development of Integrated MEasurement Systems), which started on January 1st, 2019.  To quote our EU documentation, the overall aim of DIMES is ‘to develop and demonstrate an automated measurement system that integrates a range of measurement approaches to enable damage and cracks to be detected and monitored as they originate at multi-material interfaces in an aircraft assembly’.  In simpler terms, we are going to take the results from the INSTRUCTIVE project, integrate them with other existing technologies for monitoring the structural health of an aircraft, and produce a system that can be installed in an aircraft fuselage and will provide early warning on the formation of cracks.  We have two years to achieve this target and demonstrate the system in a ground-based test on a real fuselage at an Airbus facility.  This was a scary prospect until we had our kick-off meeting and a follow-up brainstorming session a couple of weeks ago.  Now, it’s a little less scary.  If I have scared you with the prospect of cracks in aircraft, then do not be alarmed; we have been flying aircraft with cracks in them for years.  It is impossible to build an aircraft without cracks appearing, possibly during manufacturing and certainly in service – perfection (i.e. cracklessness) is unattainable and instead the stresses are maintained low enough to ensure undetected cracks will not grow (see ‘Alan Arnold Griffith’ on April 26th, 2017) and that detected ones are repaired before they propagate significantly (see ‘Aircraft inspection’ on October 10th, 2018).

I should explain that the ‘we’ above is the University of Liverpool and Strain Solutions Limited, who were the partners in INSTRUCTIVE, plus EMPA, the Swiss National Materials Laboratory, and Dantec Dynamics GmbH, a producer of scientific instruments in Ulm, Germany.  I am already working with these latter two organisations in the EU project MOTIVATE; so, we are a close-knit team who know and trust each other  – that’s one of the keys to successful collaborations tackling ambitious challenges with game-changing outcomes.

So how might the outcomes of DIMES be game-changing?  Well, at the moment, aircraft are designed using computer models that are comprehensively validated using measurement data from a large number of expensive experiments.  The MOTIVATE project is about reducing the number of experiments and increasing the quality and quantity of information gained from each experiment, i.e. ‘Getting Smarter’ (see post on June 21st 2017).  However, if the measurement system developed in DIMES allowed us to monitor in-flight strain fields in critical locations on-board an aircraft, then we would have high quality data to support future design work, which would allow further reductions in the campaign of experiments required to support new designs; and we would have continuous comprehensive monitoring of the structural integrity of every aircraft in the fleet, which would allow more efficient planning of maintenance as well as increased safety margins, or reductions in structural weight while maintaining safety margins.  This would be a significant step towards digital twins of aircraft (see ‘Fourth industrial revolution’ on July 4th, 2018 and ‘Can you trust your digital twin?’ on November 23rd, 2016).

The INSTRUCTIVE, MOTIVATE and DIMES projects have received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreements No. 685777, No. 754660 and No. 820951 respectively.

The opinions expressed in this blog post reflect only the author’s view and the Clean Sky 2 Joint Undertaking is not responsible for any use that may be made of the information it contains.


Middleton CA, Gaio A, Greene RJ & Patterson EA, Towards automated tracking of initiation and propagation of cracks in Aluminium alloy coupons using thermoelastic stress analysis, J. Non-destructive Testing, 38:18, 2019


Press release!

A jumbo jet has about six million parts of which roughly half are fasteners – that’s a lot of holes.

It is very rare for one of my research papers to be included in a press release on its publication.  But that’s what has happened this month as a consequence of a paper being included in the latest series published by the Royal Society.  The contents of the paper are not earth shattering in terms of their consequences for humanity; however, we have resolved a long-standing controversy about why cracks grow from small holes in structures [see post entitled ‘Alan Arnold Griffith‘ on  April 26th, 2017] that are meant to be protected from such events by beneficial residual stresses around the hole.  This is important for aircraft structures since a civilian airliner can have millions of holes that contain rivets and bolts which hold the structure together.

We have used mechanical tests to assess fatigue life, thermoelastic stress analysis to measure stress distributions [see post entitled ‘Counting photons to measure stress‘ on November 18th, 2015], synchrotron x-ray diffraction to evaluate residual stress inside the metal and microscopy to examine failure surfaces [see post entitled ‘Forensic engineering‘ on July 22nd, 2015].  The data from this diverse set of experiments is integrated in the paper to provide a mechanistic explanation of how cracks exploit imperfections in the beneficial residual stress field introduced by the manufacturing process and can be aided in their growth by occasional but modest overloads, which might occur during a difficult landing or take-off.

The success of this research is particularly satisfying because at its heart is a PhD student supported by a dual PhD programme between the University of Liverpool and National Tsing Hua University in Taiwan.  This programme, which supported by the two partner universities, is in its sixth year of operation with a steady state of about two dozen PhD students enrolled, who divide their time between Liverpool, England and Hsinchu, Taiwan.  The synchrotron diffraction measurements were performed, with a colleague from Sheffield Hallam University, at the European Synchrotron Research Facility (ESRF) in Grenoble, France; thus making this a truly international collaboration.


Amjad K, Asquith D, Patterson EA, Sebastian CM & Wang WC, The interaction of fatigue cracks with a residual stress field using thermoelastic stress analysis and synchrotron x-ray diffraction experiments, R. Soc. Open Sci. 4:171100.