A review of fatigue damage detection and measurement techniques

•Review of fatigue damage detection and measurement techniques.•Fatigue crack monitoring and fatigue damage monitoring.•Quantification of physical and mechanical changes of the materials during fatigue.•Acoustic emission, hardness, ultrasonic, magnetic, and potential drop for in-situ measurements.•Positron annihilation and X-ray diffraction for laboratory assessments. A vast amount of research has been carried out towards the goal of quantifying changes related to the fatigue damaging process in materials throughout the fatigue life. However, no recommended practice has been developed for the experimental measurement of fatigue damage before a macroscopic crack has been initiated. Therefore, this paper reviews the existing fatigue damage detection and measurement techniques on the basis of both momentum within the research field and their being considered non-destructive. The techniques are separated into two categories, namely, fatigue crack monitoring and fatigue damage monitoring. The parameters of these techniques, which quantify the physical and mechanical changes of the materials during the fatigue life, were critically reviewed in regard to the mechanism behind the change, limitations, shortcomings, etc. The acoustic emission, hardness, ultrasonic, magnetic and potential drop methods are applicable for in-situ measurements while positron annihilation and X-ray diffraction are more suitable for laboratory assessments. Even though all the revived methods are applicable for metals, acoustic emissions, X-ray diffraction, ultrasonic, strain-based and thermometric methods are also suitable for composites. The reliability, advantages, weaknesses, case/material dependency and applicability of each method are compared and tabulated for making a framework for choosing suitable technique for fatigue crack or damage detection of material or components.