Abstract: A potentiostat data link (PDL) unit is provided which can remotely monitor the formation and growth of cracks in metal structures. A PDL includes a sealed box containing two or more modified potentiostats, a power supply, a CPU, a memory device, and computer networking capability. The PDL can be mounted in a remote, difficult-to-access location. Each potentiostat has a lead to a sensor affixed to a structure to be analyzed for the presence of growing cracks due to metal fatigue in a metal structure.

Abstract: A potentiostat data link (PDL) unit is provided which can remotely monitor the formation and growth of cracks in metal structures. A PDL includes a sealed box containing two or more modified potentiostats, a power supply, a CPU, a memory device, and computer networking capability. The PDL can be mounted in a remote, difficult-to-access location. Each potentiostat has a lead to a sensor affixed to a structure to be analyzed for the presence of growing cracks due to metal fatigue in a metal structure.

Abstract: A method for determining a fatigue status of a growing crack in a substrate. An electrochemical sensor device is provided and includes an electrode formed from a stainless steel mesh. The electrochemical device has a bottom surface that contacts the substrate. The bottom surface is coated with an adhesive layer, and a release paper is attached to the adhesive layer. The release paper is separated from the adhesive layer, thereby exposing the adhesive layer. The electrochemical sensor device is secured to the substrate by bringing the adhesive layer in contact with the substrate and thereby forming an electrolyte cavity bounded in part by the substrate. The adhesive seals the bottom surface of the device to the substrate in order to prevent leakage of electrolyte from the cavity. The cavity is filled with the electrolyte.