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Components made of fibre-reinforced plastic are a prominently used material in modern safety-relevant structures. Periodic in-service non-destructive inspection of these structures is necesary. The EMRP-funded project VITCEA aims on the evaluation of the performance of various non-destructive testing methods on the inspection of fibre-reinforced plastics.
The physical layout of fibre layers leads to complex structures of fibre-reinforced plastic parts. Furthermore different material properties of the fibre and the resin cause anisotropic behaviour of the material.This poses a challenge for ultrasonic NDT by causing a complex acoustical response.
The acoustical behaviour of fibre-reinforced plate materials has been simulated. Specimens with artificial flaws for the evaluation of the detection thresholds have been designed and manufactured.
Mechanized ultrasonic testing methods using phased-array sensors, air-coupled transducers, immersion tank testing and contact technique have been evaluated on the specimen.
In this talk results of different ultrasonic testing methods will be compared and discussed.
Defect recognition in CFRP components using various NDT methods within a smart manufacturing process
(2017)
The manufacturing process of carbon fiber reinforced polymer (CFRP) components is playing 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 are e.g. porosity and voids which may lead to delaminations during operation and under load. To find those defects in an early stage of the manufacturing process is of huge 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 present various NDT methods which are applied to similar CFRP laminate samples in order to detect and characterize 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 of flaws, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method to apply is made by the process itself. 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 ideas 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.
Among the photothermal methods, full-field thermal imaging is used to characterize materials, to determine thicknesses of layers, or to find inhomogeneities such as voids or cracks. The use of classical light sources such as flash lamps (impulse heating) or halogen lamps (modulated heating) led to a variety of nondestructive testing methods, in particular lock-in and flash-thermography.
In vertical cavity surface emitting lasers (VCSELs), laser light is emitted perpendicular to the surface with a symmetrical beam profile. Due to the vertical structure, they can be arranged in large arrays of many thousands of individual lasers, which allows power scaling into the kilowatt range. Recently, a high-power yet very compact version of such a VCSEL-array became available that offers both the fast timing behavior of a laser as well as the large illumination area of a lamp.
Moreover, it allows a spatial and temporal control of the heating because individual parts of the array can be controlled arbitrarily in frequency, amplitude, and phase. In conjunction with a fast infrared camera, such structured heating opens up a field of novel thermal imaging and testing methods. As a first demonstration of this ansatz, we chose a testing problem very challenging to conventional thermal infrared testing: The detection of very thin subsurface defects perpendicularly oriented to the surface of metallic samples. First, we generate destructively interfering thermal wave fields which are then affected by the presence of defects within their reach. It turned out that this technique allows highly sensitive detection of subsurface defects down to depths in excess of the usual thermographic rule of thumb, with no need for a reference or surface preparation.