In this study a structural health monitoring (SHM) fastener, with built-in eddy current sensors for in-situ monitoring of fatigue cracks at hole locations in layered metallic joints was developed. This presents an optimal method of sensor integration for early stage detection of these cracks, which are among of the most common forms of damage in airframes. Thin, conformable eddy current sensors optimized for in-hole flaw detection [1] and a method of mechanical integration and complete data acquisition and software system are discussed. Results from fatigue tests of single layer and multi-layer specimens are presented in addition to results from bench-top flaw detection tests as a means of experimental validation of the system.

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