Quality Control Approach for the Detection of Internal Lower Density Areas in Composite Disks in Industrial Conditions Based on a Combination of NDT Techniques

Abstract

Voids in polymer matrix composites are one of the most common manufacturing defects, which may influence the mechanical properties and structural behavior of the final parts made of composites by various manufacturing methods. Therefore, numerous non-destructive testing (NDT) techniques were developed and applied for quality control and in-service testing of such structures. In this paper, the authors analyzed various alternatives to the reference technique, X-ray computed tomography (XCT) NDT, which is used for industrial testing of composite disks having defects in the form of the lower density areas. Different candidates, namely: vibration-based testing, infrared thermography, vibro-thermography, as well as ultrasonic testing were analyzed in terms of their sensitivity and technical feasibility. The quality of the results, the complexity of the testing procedure, time and labor consumption, and the cost of the equipment were analyzed and compared with the reference technique. Based on the conducted research the authors finally proposed a hybrid approach to quality control, using a combination of two NDT techniques–infrared thermography (for initial scanning and detection of near-surface defects) and ultrasonic testing (for a more detailed analysis of products that pass the first testing procedure). It allowed for replacing the costly XCT diagnostics with a much cheaper, but almost equally effective, alternative.

Nondestructive testing and evaluation techniques of defects in fiber-reinforced polymer composites: A review

“…In another research, the TSA ability to inspect adhesive damage in lap joints was demonstrated to be beneficial for long-term fatigue tests or comparing the mechanical performance of various FRPCs joints (Johnson, 2014). (Katunin et al, 2021) used vibro-thermography to investigate voids, which exist in composite disks in the form of lower-density areas. The excitation of vibro-thermography was mechanical vibrations provided by an electrodynamic shaker with a frequency equal to the natural frequency at maximum vibration amplitude.…”

“…Recent studies have demonstrated Frontiers in Materials frontiersin.org that improving available technologies by combining different NDT&E techniques and fusion data is a potential approach for complex composite structures. For example, a combined NDT&E method consisting of IRT (for initial scanning and detection of near-surface defects) and UT (for a more detailed analysis of products that pass the first testing procedure) can improve detection accuracy (Katunin et al, 2021). UT and X-ray CT results can be used in evaluating impact damage in composite structures (Katunin et al, 2020).…”

Mechanical Fatigue Testing Under Thermal Gradient and Manufacturing Variabilities in Nickel-Based Superalloy Parts with Air-Cooling Holes

“…To appreciate 3D defects and geometrical shape, Computed Tomography (CT) is used. X-Ray (XR) projections (called radiographies) of the part are taken at different angles and reconstruction algorithms are applied to access to 3D volume of the piece where geometrical control can be applied through image processing techniques [25][26][27]. Although grain selector restrict crystal primary orientation, a misorientation can still occur during casting and have a major impact on mechanical behaviour.…”

Defect Detection Method of Carbon Fiber Sucker Rod Based on Multi-Sensor Information Fusion and DBN Model

“…Due to the irregular interfaces between the CFRP and GFRP, defect inspection of the carbon fiber sucker rod is very difficult. Some Nondestructive Testing (NDT) techniques have been developed for composite diagnostic purposes [4][5][6]. Because Ultrasonic Nondestructive Testing (UNDT) has the advantages of high detection accuracy, convenient use, simple operation, and wide application range [7], it has become one of the most accepted methods for composite inspection.…”

“…Castellano [13] performed ultrasonic goniometric immersion tests in order to characterize mechanically the substrate and the new material obtained by the additive manufactured process. Combined with the CT imaging principle, Zhou [14] developed an imaging method based on probabilistic damage for the Some Nondestructive Testing (NDT) techniques have been developed for composite diagnostic purposes [4][5][6]. Because Ultrasonic Nondestructive Testing (UNDT) has the advantages of high detection accuracy, convenient use, simple operation, and wide application range [7], it has become one of the most accepted methods for composite inspection.…”