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Conductive graphene polymer composites are considered promising functional materials in gas detection, strain detection, metal corrosion prevention, and electromagnetic wave absorption, owing to their good flexibility, lightweight, and adjustable conductivity. The internal defects or external damages of composite films will seriously affect the electrical and functional properties of the materials. Based on the conductive network inside the conductive polymer film and the self-inductance to ultrasonic wave, the defect self-monitoring system of the conductive polymer film is designed and optimized in this work. The self-damage detection system is composed of an electrode array, excitation source, resistance signal acquisition and processing circuit, and damage display. Aiming at different scenarios, the improved interdigital structure transducer for sensors and damage detection device for coating film with a large area are presented and optimized respectively. Meanwhile, the damage location algorithm based on time difference measurement and kernel density estimation algorithm is also optimized. The multiple damage detection is realized by a device with a 4 × 8 electrode array, and the relative error of damage area with 1 mm × 1 mm is less than 5%, and the lower detection limits of damage size are 0.3 mm × 0.3 mm.

Hole-edge crack quantification of bolt joints is critical for monitoring and estimating structural integrity of aircraft. The paper proposes a new triangle eddy current sensor array for the purpose of increasing the level of quantifying hole-edge crack parameters, especially, the crack angle. The new senor array consists of triangular coils instead of planar rectangular coils. The configuration of the novel sensor array, including the excitation current directions and the excitation winding shape, is optimized by simulation. The ability of the proposed sensing film to identify the crack parameters has been verified by finite element simulations and experiments. Results shows that triangular coils with same current directions in circumferentially adjacent coils and opposite current directions in axially adjacent coils achieve better performance in sensor linearity and resolution compared to rectangular coils. In addition, it has also been proved that the sensing film has a good potential to identify the crack depth and length.