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Modern and energy-efficient materials are essential for innovative designs for aerospace and automotive industries. Current technologies for rapid manufacturing such as additive manufacturing and liquid composite moulding by polymer Extrusion allow innovative ways of creating robust and lightweight constructions. Commercially available printing devices often use polylactide (PLA) or acrylonitrile butadiene styrene (ABS) as raw material. Therefore, parameters like the infill ratio, influencing the ability to resist mechanical stress, may have a beneficial impact on the lifetime of components.
These manufacturing technologies require a good knowledge about materials and even adapted non-destructive testing technologies and methods. Airborne ultrasonic testing has beneficial advantages for testing those lightweight constructions. It is a contact-free testing method, which does not require a liquid couplant. Therefore, it allows fast test cycles without any unwanted alternations of the material properties due to interactions with any coupling liquid. This contribution deals with the characterisation of printed specimens based on PLA by using airborne ultrasound and presents the current edge of non-destructive testing and evaluation using airborne ultrasonic transducers. The specimens, manufactured by polymer extrusion, are printed as thin plates. The infill ratio, as well as the material thickness, were varied to model density imperfections with different geometric shapes and properties. For better understanding of the limits of airborne ultrasonic testing in transmission, we compared own-developed transducers based on different physical principles: on ferroelectrets, on the thermoacoustic effect, as well as a new type of transducers based on gas discharges.
This presentation is an overview of experimental realization of air-coupled ultrasonic testing. Focusing transducers based on ferroelectrets are presented. Inspection results of natural defects like impact damage and delamination of composite structures are shown and challenges relating to the propability of detection of defects are pointed out.
Rising importance of composite lightweight structures in aircraft and automobile industries increases the demand on reliable non-destructive testing methods for these structures. Air-coupled ultrasonic testing emerged to suit these requirements as it does not require any liquid coupling medium. In conventional air-coupled ultrasonic transducers, matching layers are used in order to decrease the impedance mismatch between transducer and air. Matching layers can be omitted by using ferroelectrets, which are charged cellular polymers having ferroelectric and piezoelectric properties. Especially a low Young’s modulus, low density and low sound velocity of cellular polypropylene (cPP) are properties being required for well-matched air-coupled ultrasonic transducers. In our contribution we show recent enhancements of cPP transducers resulting in focused sound fields and thus improved lateral sensitivity. The influence of different transmitter apertures was evaluated using measurements of the emitted sound field. Further we show a transmission of a test specimen of carbon-fiber-reinforced plastic (CFRP) containing artificial damages. Results of focused transducers were compared to planar ferroelectret transducers, as well as to conventional air-coupled transducers.
Rising importance of composite lightweight structures in aircraft and automobile industries increases the demand on reliable non-destructive testing methods for these structures. Air-coupled ultrasonic testing emerged to suit these requirements as it does not require any liquid coupling medium. In conventional air-coupled ultrasonic transducers, matching layers are used in order to decrease the impedance mismatch between transducer and air. Matching layers can be omitted by using ferroelectrets, which are charged cellular polymers having ferroelectric and piezoelectric properties. Especially a low Young’s modulus, low density and low sound velocity of cellular polypropylene (cPP) are properties being required for well-matched air-coupled ultrasonic transducers.
In our contribution we show recent enhancements of cPP transducers resulting in focused sound fields and thus improved lateral sensitivity. The influence of different transmitter apertures was evaluated using measurements of the emitted sound field. Further we show a transmission of a test specimen of carbon-fiber-reinforced plastic (CFRP) containing artificial damages. Results of focused transducers were compared to planar ferroelectret transducers, as well as to conventional air-coupled transducers.