Fracture detection on coach frame welding joints with piezoelectric composite coating

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Motor Coach Industries (MCI) is facing a problem to detect possible fractures at coach frame welding joints while the coach is in operation and without stripping off the coating materials of the coach. In addition, since multiple joints are usually found to be broken during maintenance, it is desirable for them to identify which joint fractures first because it can lead to fracturing at other joints. In this project, a piezoelectric composite coating will be designed and applied on the welding joints of coach frame structures. The coating should be easily applied on the rough surface of the welding joints and will send warning signals automatically, when the fracture takes place on the welding joint that the coating is applied. The techniques is developed and tested by my research group, but its application on the real engineering structures will be further tested and proven with the help of the engineers and technicians from MCI. The success of this project will help MCI to save cost on fractures identification without stripping off the coating materials of the coach. By noticing the first fracture happening, the technique could also guide MCI's maintenance schedule so as to avoid further frame factures and the expensive repair progress.