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NDT of Composites

The document discusses non-destructive testing (NDT) of aerospace composites. It covers topics like material knowledge, common NDT methods used for composite inspection such as ultrasonic testing and bond testing, damage assessment, test standards, and training. The document is presented by John D. Register from R-CON NDT Inc. and provides an overview of composites and how to properly inspect them using NDT techniques.

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550 views20 pages

NDT of Composites

The document discusses non-destructive testing (NDT) of aerospace composites. It covers topics like material knowledge, common NDT methods used for composite inspection such as ultrasonic testing and bond testing, damage assessment, test standards, and training. The document is presented by John D. Register from R-CON NDT Inc. and provides an overview of composites and how to properly inspect them using NDT techniques.

Uploaded by

jamariekoni
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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NDT of Aerospace

Composites
by
John D. Register,
R-CON NDT Inc.

11/24/2005 R-CON NDT Inc. 1


R-CON NDT Inc.
„ Training
Basic NDT Training and NDT of Composites

„ Consulting
Level III – NDT Programs -

„ Equipment Sales
Portable – Large Scanning

11/24/2005 R-CON NDT Inc. 2


Topics of Discussion
„ Material and defect knowledge
„ NDT Methods used for Inspection of
Composite materials
‹ Focus on Ultrasonic and Bond Testing
„ Damage Assessment
„ Test Standards
„ Training

11/24/2005 R-CON NDT Inc. 3


Introduction
„ Composite Materials have been used in
aircraft since the early days
„ Fiberglass, Aluminum core materials on DC-
9 and 727 A/C
„ New programs such as 787 and the JSF
have heighten the need for testing of
Composites
„ NDT of Composites is still a relatively
unknown area

11/24/2005 R-CON NDT Inc. 4


What are Composite Materials
„ A composite material by definition is the
combination of two or more materials.
„ Example:
‹ Clay = Straw and Brick
„ Real World Examples
‹ Fiberglass Corvette Body (E-Glass and resin)
‹ Carbon Bicycle Frame (Carbon and resin)

‹ Laminate and Bonded A/C materials

11/24/2005 R-CON NDT Inc. 5


Material Knowledge
Defects: Sampling
„ Delaminations: Separation of the layers of material in a
laminate, either local or covering a wide area.

„ Disbond/Unbond: An area within a bonded interface


between two adherents in which adhesion failure or
separation has occurred.

„ Porosity: A condition of trapped air, gas or vacuum within a


solid material.

„ Crack: An actual separation of material visible on opposite


surfaced of the part, and extending through the thickness. A
fracture.
11/24/2005 R-CON NDT Inc. 6
Material Knowledge
„ Laminates

„ Sandwich Structure

11/24/2005 R-CON NDT Inc. 7


Laminate
GR/Epoxy or Glass Laminate

Delams

11/24/2005 R-CON NDT Inc. 8


Sandwich Structure
GR/Epoxy Laminate Nomex Core

Delam
Delam Core Crush

Disbond

Delam
11/24/2005 R-CON NDT Inc. 9
NDT Methods
„ Visual Inspection: Using the eye alone or in conjunction
with aids

„ Ultrasonic Testing: Most Common NDT Method for the


inspection of Composites

„ Bond Testing: Single sided Bond Testing utilizing Pitch


Catch or Resonance testing modes

„ Tap Testing: Oldest and simplest method of Bond Testing.


Viable method, Need to understand limitations

11/24/2005 R-CON NDT Inc. 10


NDT Methods Con’t

„ Radiography: Detects changes in material density.


Typically used in core inspection.

„ Thermography: Detects local increases or decreases in


heat capacity or thermal conductivity
www.thermalwave.com

„ Laser Shearography: Detects local stress areas by utilizing


heat or vacuum to change the surface structure.
www.laserndt.com

11/24/2005 R-CON NDT Inc. 11


Ultrasonic Inspection
Ultrasonic is based on the Principal of transmitting high
frequency sound into a test part and monitoring the received
ultrasonic energy.

„ U.T Portable equipment techniques:


‹ Pulse Echo - Laminate Inspection
‹ Through Transmission – Bonded Panels

Composite Inspection:
Freq Range 1.0 Mhz – 5 Mhz
Good Near Surface Resolution

www.sonatest.com
11/24/2005 R-CON NDT Inc. 12
Ultrasonic Inspection
Large Area Scanner

High Scanning speeds

Larger scan areas

Pulse Echo

Through
Transmission

11/24/2005 www.sdindt.com
R-CON NDT Inc. 13
Bond Testing
Modes: Pitch Catch Resonance

Disbonds/Unbonds Delams/Disbonds/Unbonds
Zetec Miz 21 SR. www.zetec.com
11/24/2005 R-CON NDT Inc. 14
Damage Assessment

11/24/2005 R-CON NDT Inc. 15


Damage Assessment

Delam
Disbond
T T

R R
11/24/2005 R-CON NDT Inc. 16
Damage Assessment

Delam
Disbond

11/24/2005 R-CON NDT Inc. 17


Test Standards
„ Standards should represent the part under
test:
‹ Manufacturing Method
‹ Material

„ Standards should contain induced flaws that


represent type of defect sought.
„ In some cases the part can be used as the
test standard

11/24/2005 R-CON NDT Inc. 18


Training
„ Training is required for Technicians testing
Aerospace Composites

„ Composite Inspection differs from Metallics

„ Equipment considerations are key to


successful Inspection of Composites

11/24/2005 R-CON NDT Inc. 19


Contact Information
R-CON NDT
Booth Number 2079 NDT Zone

www.rcon-ndt.com

[email protected]

11/24/2005 R-CON NDT Inc. 20

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