NDT Technologies for Composite Manufacturing

September 19, 2014

1

Aerospace Non-Destructive Testing (NDT) Research Laboratory

NDT Technologies for Composite Manufacturing

Speaker Dr. Andrei Anisimov Head of the laboratory Dr. Roger Groves

Faculty of Aerospace Engineering

Aerospace NDT Research Laboratory at TUD • Setup in 2008 and headed by Dr Roger Groves • Research Team: 4 Postdocs, 5 PhDs, 7 Project students • Interdisciplinary & international research team • Facilities: 150 m2 Laboratory space, 1 M€ equipment

September 19, 2014 2

Aerospace NDT Research Topics at TUD 1. Optical Metrology: Dr Andrei Anisimov

• Shearography, Fringe projection, Dimensional measurement 2. Fibre Optic Sensors: Ping Liu, MSc

• Optical coherence tomography, FBGs, Structural health monitoring 3. Spectral Imaging: Dr Vassilis Papadakis

• Hyperspectral imaging, Fibre optic reflectance spectroscopy 4. Ultrasonics: Dr Roger Groves

• Phase-array ultrasound, Guided Lamb waves 5. Laser Processing: Dr Roger Groves

• High power laser for composites machining & drilling


NDT for Composites. Transport


Aerospace Rail transport

Automotive Shipbuilding

NDT of composites and GLARE

NDT of advanced vehicles geometry

NDT of advanced ship composites

Main applications

Objective: developing green, safe, efficient and accessible transport networks

NDT laboratory key capabilities: • Research and development of joint measuring techniques • Data fusion and visualisation • Development of control & processing algorithms • Field and on-site measuring and inspecting techniques

NDT for Composites. Energy


Strain and vibration monitoring

Objective: developing green energy solutions and improving energy efficiency

NDT laboratory key capabilities: • Structural health monitoring • Autonomous and robust sensor networks

(incl. energy harvesting) for 24/7 long term control • Integrated and embedded sensors • Materials and structures life time estimation and behaviour

prediction

Wind turbines High voltage insulators

Oil and gas pipeline composite repair

Main applications

NDT of solar panels

NDT for composites • Reinforcement

• Orientation / Breaks / Waviness • Matrix

• State-of-cure / Porosity / Cracking • Interface

• Debonding / Delamination / Moisture ingress • Geometry and Strain

• Shape / Geometry / Position • Surface strain

• Structure • Global inspection / Proof tests


Detection

Localization

Characterization

Aerospace NDT Laboratory Key Technologies


Optical Metrology

Interferometry (incl. speckle interferometry and shearography)

Fringe projection and photogrammetry

Dimensional measurement

Fibre Optic Sensors

Optical coherence tomography

Fibre Bragg gratings

Spectral Imaging Hyperspectral imaging

Ultrasonics

Conventional and phased array ultrasonics

Lamb waves (incl. guided)

Multiple view geometry

Structural health monitoring

Linescan & point shape sensors

Infrared thermography (incl. flash)

Terahertz imaging

Outline 1. Optical Metrology

2. Fibre Optic Sensors

3. Spectral Imaging

4. Ultrasonics

Conclusion


1. Optical Metrology a. Linescan & point shape sensors

i. Shape measurement (scanning sensors)

b. Fringe projection i. Shape measurement (camera-based)

c. Shearography i. Non-destructive testing ii. Displacement gradient & strain measurement iii. Vibration characteristion (full-field)


1a. Linescan/Point Shape Sensors


Application: manufacturing layup of composite materials Accuracy to 2,6 µm 0

0,5

1

1,5

0 50 100 150

Hei

ght

(mm

)

Y-axis (mm)

Detection of enclosed foil

1b. Fringe Projection


• AIM: High precision 3D shape control of parts and assemblies geometry with accuracy to 50 µm

1c. Shearography


2 Points on the object = 1 Pixel on the camera

1c. Shearography – Measurement Process


Reference Signal

[ [ ] ] – = Phase map Random reference phase map Random signal phase map

1c. Shearography – Non-Destructive Testing


• AIM: Location of non-visible impact damage defect in an aerospace composite panel • Loading by infra-red lamp

10 seconds 24 seconds 44 seconds

1c. Shearography - Vibration Characterisation • AIM: Determination of resonant frequencies for a compressor turbine blade (time-

average analysis)


2.74 kHz (Blade flap)

4.45 kHz (Corner/side flap)

5.06 kHz (Whole blade resonance)

11.94 kHz (large amplitude corner/side flap)

Interferometer 1

Interferometer 2

Interferometer 3

Interferometer 4

Sample

Laser

1c. 3D shearography


X-shear phase map

Y-shear phase map

The displacement gradient components:

, 11

, 2

, 3

12

y cam

y y cam

y cam

dudy

Mdy

dwdy

φλε φπ

φ

−

∆ = − ∆ ∆

, 11

, 2

, 3

12

xx cam

x cam

x cam

dv Mdx dxdwdx

ε φλ φπ

φ

−

∆ = − ∆ ∆



3. Spectral Imaging

4. Ultrasonics

Conclusion


2. Fibre Optic Sensors Research Topics

a. Optical Coherence Tomography (OCT)

i. Coating thickness measurement ii. 3D materials characterisation

b. Fibre Bragg Gratings (FBGs) i. Embedded control system ii. Multi-parameter strain and vibration measurement


2a. Optical Coherence Tomography - Medical


2a. Optical Coherence Tomography for NDT


Volumetric images and 3D crack profiles during delamination growth in a glass fibre composite

2a. Optical Coherence Tomography for NDT


(a) cross-sectional image and (b) one depth profile of an epoxy coating


2b. FBG (Fibre Bragg Grating) • Each FBG sensor reflects narrow wavelength spectrum • Wavelength shifts due to strain change

Input spectrum

Transmitted spectrum

Core UV inscribed holographic grating FBG

Cladding

Reflected spectrum


2b. FBG – Multi-parameter + embedded

• AIM: Multi-parameter measurement for composites NDT

• Simultaneous measurement of: • Bending • Tension or Compresion • Vibration

Examples of fibres embedded to composites



3. Spectral Imaging

4. Ultrasonics

Conclusion


3. Instrumentation used (for Imaging)

THz (100 µm -> 1 mm)


3. Hyperspectral Imaging • Objective: detection of surface contamination prior to bonding, coating, painting

or welding using hyper-spectral imaging techniques


Benefits: reduction in flaws and rework due to contamination

http://www.andersonmaterials.com

http://textron.com

Peel specimens: -left – bad adhesion and surface contaminations -right – intra-laminar failure, good adhesion and no contamination



3. Spectral Imaging

4. Ultrasonics

Conclusion


4. Ultrasonics Research Topics

a. Guided Lamb wave ultrasonics

i. NDT of composites ii. Time-reversal Lamb wave iii. Air-coupled ultrasonics

b. Phase-Array Ultrasonics i. Damage detection in composites

c. Data Fusion

28 September 19, 2014


4a. Lamb Waves – NDT of Laminated Composites • Damage detection of multiple-location barely visible impact damage (BVID)

4a. Guided Lamb Wave Ultrasonics • Non-Contact NDT using Air-Coupled Sensors • Air-coupled transducers, with automated, e.g. robot, positioning allow non-contact

high-speed damage detection in production environments • Damage detection algorithms applied to received ultrasonic signals

Setup for air-coupled ultrasonics


4b. Phased Array Ultrasonics


Automated setup for ultrasonic phased array NDT

UT phased array probe

Composite panel

XY motion control unit with encoders



C-scan of complex carbon fibre structure


Comparison of C-scans of GLARE panel obtained with 2.25 (“near wall”) and 5 MHz phased array probes


4c. Data Fusion (C-scan and shape) Fusion of ultrasonic C-scan and shape data of GLARE panels Shape

UT C-scan

34 September 19, 2014



3. Spectral Imaging

4. Ultrasonics

Conclusion


Future research

• Research and development of joint measuring techniques

• Data fusion and 3D visualisation

• Development of robust flaw detection and characterisation algorithms

from fused data

• Implementation of autonomous, integrated and embedded sensor networks

(incl. energy harvesting) for 24/7 long term control



Speaker • Dr. Andrei Anisimov • E-mail: [email protected] • Telephone: +31 15 278 8233 +7 921 793 6524

Head of the laboratory • Dr. Roger Groves • E-mail: [email protected] • Telephone: +31 15 278 8230

Aerospace Non-Destructive Testing (NDT) Research Laboratory

Thank you for your attention! Questions?

Faculty of Aerospace Engineering Delft University of Technology Webpage: optondt.tudelft.nl

mailto:[email protected]

mailto:[email protected]

http://www.optondt.tudelft.nl/

Date post:	05-Nov-2023
Category:	Documents
Upload:	tudelft
View:	0 times
Download:	0 times

NDT Technologies for Composite Manufacturing

Documents