Skip to main content
European Commission logo
TRIMIS

Cost Effective Corrosion and Fatigue Monitoring for Transport Products

Project

CORFAT - Cost Effective Corrosion and Fatigue Monitoring for Transport Products


Funding origin:
European
European Union
STRIA Roadmaps:
Vehicle design and manufacturing (VDM)
Vehicle design and manufacturing
Transport mode:
Multimodal
Multimodal
Transport sectors:
Passenger transport
Passenger transport
Freight transport
Freight transport
Project website:
Duration:
Start date: 01/11/2008,
End date: 01/10/2012

Status: Finished
Funding details:
Total cost:
€4 188 928
EU Contribution:
€2 817 335

Overview

Background & policy context:

The background of this project is related to technical safety in conjunction with the competitiveness of the EU industry. Corrosion damages and fatigue cracks are the main causes for structural failures of all surface transport products such as, ships, road tankers and railway tank cars. Examples are catastrophic ship accidents with a tremendous pollution of the maritime environment or fatal explosions during the use of transport vehicles. To prevent structural failures, maintenance and inspection has to be carried out. These activities require high efforts and are usually performed while the transport product is out of service. Such kinds of maintenance are often referred to as "preventive maintenance". Defects have to be identified in time to enable appropriate repair. However, preventive maintenance activities are usually carried out on a time driven or routine basis.

As an example, transport products for cargo such as, crude oil and pressurised gases have to be taken out of service for visual inspection and subsequent non-destructive tests (NDT). Findings then have to be repaired at a later stage. This procedure is time-consuming and expensive, especially so, as the lost service time decreases the competitiveness of the European transport industry. Despite this high effort, the risk of not detecting the onset of a defect is still implied in this maintenance process and thus failure within the next service period may occur.

Objectives:

It has been proven that Acoustic Emission (AE) technology detects active cracks and enables the evaluation of active corrosion. By the application of permanent AE sensors on predetermined hot spots of ships and tank cars, the conventional maintenance and inspection can be replaced by a cost effective and condition-based detection of defects and their follow-up in time.

The main objectives of the project were:

  • Final prototype of monitoring equipment for transport products;
  • Generic maintenance and an inspection programme using the AE monitoring technology;
  • Drafts for standardisation.

Methodology:

The proposed maintenance process has been based on monitoring the status of the structural integrity in terms of developing fatigue cracks and active corrosion using the Acoustic Emission (AE) technology. It has been proven that AE detects active cracks and based on the results of EU-funded project Corrosion Detection of Ships (EVG1-CT-2002-00067), it is evident that AE is able to detect and evaluate active corrosion, allowing countermeasures to be implemented much sooner. This means on the one hand, more safety and on the other, a larger saving of resources.

By the permanent application of AE sensors (on pre-determined hot spots) the conventional maintenance and inspection can be replaced by a cost-effective and condition-based detection of defects and their follow-up in time. The result of the project was an overall strategy for the maintenance and inspection, including the necessary AE equipment for the different transport products. Reasonable follow-up NDT methods were validated. By the on-line measurement the method will also increase the safety of all transport products.

Contribute! Submit your project

Do you wish to submit a project or a programme? Head over to the Contribute page, login and follow the process!

Submit