TY - CONF A1 - Schumacher, David A1 - Meyendorf, N. A1 - Hakim, I. A1 - Ewert, Uwe ED - Chimenti, D. E. ED - Bond, L. J. T1 - Defect recognition in CFRP components using various NDT methods within a smart manufacturing process T2 - AIP Conference Proceedings N2 - The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of defective volume. Besides ultrasound, thermography and eddy current, different X-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the concepts of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized. T2 - 44TH ANNUAL REVIEW OF PROGRESS IN QUANTITATIVE NONDESTRUCTIVE EVALUATION CY - Provo, Utah, USA DA - 16.07.2017 KW - Carbon fiber reinforced polymers KW - Non-destructive testing KW - Smart industry (4.0) KW - Ultrasound KW - Laminography KW - Serial sectioning KW - Computed tompgraphy PY - 2018 SN - 978-0-7354-1644-4 DO - https://doi.org/10.1063/1.5031521 SN - 0094-243X VL - 1949 SP - UNSP 020024, 1 EP - 11 PB - AIP Publishing AN - OPUS4-44773 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kupsch, Andreas A1 - Trappe, Volker A1 - Nielow, D. A1 - Schumacher, David A1 - Lange, A. A1 - Hentschel, M.P. A1 - Redmer, Bernhard A1 - Ewert, U. A1 - Bruno, Giovanni T1 - X-ray laminographic inspection of sandwich shell segments for wind turbine rotor blades T2 - Proceedings 12th European conference on Non-Destructive Testing N2 - 3D structural investigations are described by X-ray laminography studies of sandwich shell segments, made of a PVC foam core, covered by non-crimp fabric glass fibre composite lay-ups processed by vacuum assisted resin infusion of epoxy. The specific scope of this study is to image transversal flaws within the foam core (joints) and of single ply overlaps. Test flaws were purposely implemented in order to simulate typical failure under cyclic load. In a dedicated test rig for shell structures, the flaw evolution/propagation is monitored by thermography and optical 3D inspection of deformation. Due to the unfavourable preconditions for classical computed tomography as of large aspect ratio, the samples were investigated by coplanar translational laminography. Its limited range of observation angles of ± 45°, results in anisotropic artefacts about the normal to the sample surface, but the typical flaws are well visualized in the as-prepared state, in a state of early damage, and in the repaired state. T2 - 12th European conference on Non-Destructive Testing CY - Gothenburg, Sweden DA - 11.06.2018 KW - X-ray laminography KW - Wind turbine KW - Rotor blade PY - 2018 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-453931 SN - 978-91-639-6217-2 SP - 1 EP - 8 AN - OPUS4-45393 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schumacher, David A1 - Sharma, R. A1 - Grager, J.-C. A1 - Schrapp, M. T1 - Scatter and beam hardening reduction in industrial computed tomography using photon counting detectors JF - Measurement Science and Technology N2 - Photon counting detectors (PCD) offer new possibilities for x-ray micro computed tomography (CT) in the field of non-destructive testing. For large and/or dense objects with high atomic numbers the problem of scattered radiation and beam hardening severely influences the image quality. This work shows that using an energy discriminating PCD based on CdTe allows to address these problems by intrinsically reducing both the influence of scattering and beam hardening. Based on 2D-radiographic measurements it is shown that by energy thresholding the influence of scattered radiation can be reduced by up to in case of a PCD compared to a conventional energy-integrating detector (EID). To demonstrate the capabilities of a PCD in reducing beam hardening, cupping artefacts are analyzed quantitatively. The PCD results show that the higher the energy threshold is set, the lower the cupping effect emerges. But since numerous beam hardening correction algorithms exist, the results of the PCD are compared to EID results corrected by common techniques. Nevertheless, the highest energy thresholds yield lower cupping artefacts than any of the applied correction algorithms. As an example of a potential industrial CT application, a turbine blade is investigated by CT. The inner structure of the turbine blade allows for comparing the image quality between PCD and EID in terms of absolute contrast, as well as normalized signal-to-noise and contrast-to-noise ratio. Where the absolute contrast can be improved by raising the energy thresholds of the PCD, it is found that due to lower statistics the normalized contrast-to-noise-ratio could not be improved compared to the EID. These results might change to the contrary when discarding pre-filtering of the x-ray spectra and thus allowing more low-energy photons to reach the detectors. Despite still being in the early phase in technological progress, PCDs already allow to improve CT image quality compared to conventional detectors in terms of scatter and beam hardening reduction. KW - X-ray computed tomography KW - Photon counting detector KW - CdTe sensor KW - Non-destructive testing KW - Beam hardening KW - Scattered radiation PY - 2018 UR - http://iopscience.iop.org/article/10.1088/1361-6501/aabef7/meta DO - https://doi.org/10.1088/1361-6501/aabef7 SN - 1361-6501 VL - 29 IS - 7 SP - 075101, 1 EP - 12 PB - IOP Publishing CY - Bristol, UK AN - OPUS4-44959 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hakim, I. A1 - Schumacher, David A1 - Sundar, V. A1 - Donaldson, S. A1 - Creuz, A. A1 - Schneider, R. A1 - Keller, J. A1 - Browning, C. A1 - May, D. A1 - Abo Ras, M. A1 - Meyendorf, N. ED - Chimenti, D. E. ED - Bond, L. J. T1 - Volume imaging NDE and serial sectioning of carbon fiber composites T2 - AIP Conference Proceedings N2 - A composite material is a combination of two or more materials with very different mechanical, thermal and electrical properties. The various forms of composite materials, due to their high material properties, are widely used as structural materials in the aviation, space, marine, automobile, and sports industries. However, some defects like voids, delamination, or inhomogeneous fiber distribution that form during the fabricating processes of composites can seriously affect the mechanical properties of the composite material. In this study, several imaging NDE techniques such as: thermography, high frequency eddy current, ultrasonic, x-ray radiography, x-ray laminography, and high resolution x-ray CT were conducted to characterize the microstructure of carbon fiber composites. Then, a 3D analysis was implemented by the destructive technique of serial sectioning for the same sample tested by the NDE methods. To better analyze the results of this work and extract a clear volume image for all features and defects contained in the composite material, an intensive comparison was conducted among hundreds of 3D-NDE and multi serial sections’ scan images showing the microstructure variation. T2 - 44TH ANNUAL REVIEW OF PROGRESS IN QUANTITATIVE NONDESTRUCTIVE EVALUATION CY - Provo, Utah, USA DA - 16.07.2017 KW - Carbon fiber reinforced polymers KW - Non-destructive testing KW - Thermography KW - Eddy current KW - Ultrasound KW - X-ray radiography KW - X-ray laminography KW - X-ray computed tomography KW - Serial sectioning PY - 2018 DO - https://doi.org/10.1063/1.5031590 VL - 1949 SP - 120003-1 EP - 120003-10 PB - AIP Publishing AN - OPUS4-45173 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schumacher, David A1 - Zscherpel, Uwe A1 - Ewert, Uwe T1 - Recent developments of photon counting and energy discriminating detectors for radiographic imaging T2 - Proceedings of 2017 Far East NDT New Technology & Application Forum (FENDT) N2 - The direct detection of X-ray photons into electrical signals is enabled by usage of highly absorbing photo conducting materials (e.g. CdTe) as detection layer of an underlying CMOS semiconductor X-ray image detector. If the read-out speed is high enough (ca. 50 - 100 ns dead time) single X-ray photons can be counted and their energy measured. Read-out noise and dark image correction can be diminished. By setting energy thresholds, selected energy ranges of the X-ray spectrum can be detected or suppressed. This allows material discrimination or reduction of scattered radiation, which results in an enhanced contrast sensitivity. T2 - Far East NDT New Technology & Application Forum (FENDT) CY - Xi'an, China DA - 22.06.2017 KW - Industrial X-ray imaging KW - Photon counting KW - Energy discrimination KW - Dual energy imaging KW - Direct detection PY - 2018 UR - https://ieeexplore.ieee.org/document/8584559 SN - 978-1-5386-1615-4 DO - https://doi.org/10.1109/FENDT.2017.8584559 VL - 2017 SP - 281 EP - 285 PB - IEEE Xplore AN - OPUS4-47175 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -