Shearography - New Possibilities in Composite Testing ...
Transcript of Shearography - New Possibilities in Composite Testing ...
![Page 1: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/1.jpg)
1
Shearography
Composite-NDT
2
„Make the invisible visible“
4th International Symposium on
NDT in Aerospace 2012 - Tu.2.A.1
Licence: http://creativecommons.org/licenses/by-nd/3.0
1
![Page 2: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/2.jpg)
3
Product lines
Shearography principle
Materials to be inspected
Defects to be found typically
Applications
Systems
References
Summary
Content of Presentation
4
3D Scanners:
Geometry (COMET & T-SCAN):
Compare (CAD data)
Measure
Distance
Radius
Shearography NDT (ISIS)
Products for Aerospace Applications
2
![Page 3: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/3.jpg)
5
Shearography
Basics & Solutions
6
Shearography
Basics & Solutions
NEW NDT METHOD
• NEW approach to NDT: Shearography (ST) method
• Enables Non-contact inspection
• Delivers Full-field results
• 1.4 Million datapoints
• Very Fast method
• Image was obtained in 10s
• Included into international inspection standards:
o NAS 410/ EN4179 (ST) training & certification standard
o ASNT SNT-TC-1A (Visual and optical testing procedure)
o ASTM E 2581-07 (Standard practice of Shearography for composites & aerospace applications)
3
![Page 4: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/4.jpg)
7
Debond
Deformation
Gradient
of Deformation
Reference Image
Resolution 30 nm
Thermal excitation
Vacuum excitation
Technical Basics – Shearographic Principle
Spatial
Gradient
of Deformation
Loading Image
Reference Image
Loading Image
Shearography Sensor
8
Fields of Application
4
![Page 5: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/5.jpg)
9
Materials To Be Inspected
Honeycomb
Foamcore Material
Glare®
Carbon - Nomex
CFRP Sandwich
Laminates
Carbon-Rohacell®
Aluminium
Honeycomb
Glass fiber -
Foam®
Sandwich Material
10
Defects To Be Found Typically
Debondings
Delaminations
Cracks
Impacts, Dents, BVID‘s
Tooldrop impacts
Failed repair areas
Wrinkles, Waves
Inclusions:
Air, Water, Foil
Foreign Material (FOD)
5
![Page 6: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/6.jpg)
11
Applications
12
C-130 Hercules
Inspeciton of CFRP/ GRP nose
Detection of delaminations
Matching results with 3D-CAD data
C-130 Hercules
6
![Page 7: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/7.jpg)
13
Delaminations
Detection of two laminate debonds
Merging and matching of results
with imported 3D CAD data
C-130 Hercules
14
100% documentation
Complete stitching of results
C-130 Hercules
7
![Page 8: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/8.jpg)
15
Shearography inspection on Tornado hull
Time saving full-field inspection method necessary in
maintenance for detection of dents and impacts
real-time image
test result
NDT on Tornado
16
Acoustic liner
material:
Detection of
laminate-honeycomb
core defects
Acoustic liner material
Full automatic testing
by stationary unit
8
![Page 9: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/9.jpg)
17
Barely visible impact damages
• Barely visible impact damages on a stringer panel
• Inspection of impact
• Damage assessment of surrounding area
18
Barely visible impact damages
Shearographic image Theoretical approach
Visible area
Cone damage in the material
CFRP Top-layer
Core material
Defect extends
into the structure
9
![Page 10: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/10.jpg)
19
Barely visible impact damages
A
C
B
20
NDT on UAV Wing
• NDT on UAV wing
• Shearography enables fastest
inspection procedure
• Defect detection with thermal excitation
10
![Page 11: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/11.jpg)
21
NDT on Drone Wing
• Two fields of dry fibres were
detected
• Flaws not visible
• Easy localization of defects
22
Nitrogen Satellite Tank
• Set-up: Optical Shearography
NDT System (ISIS1100)
• Tank measurement on cylindrical and dome area
• Detection of artificial inserts
• Radome area stiffer than cylindrical area
11
![Page 12: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/12.jpg)
23
Cylindircal area defects
• Cylindrical area inspected
• All 4 defects found
• Defects of inserts in CFRP
• Thermal excitation of 4s
24
• Thermal excitation 5s
• All 4 defects found
Radome area defects
12
![Page 13: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/13.jpg)
25
• NDT of ROHACELL® material
• Thermal excitation
• Testing time less than 15 seconds
• Carbon top skin
• Adhesive layers
• Material is used for :
• Body panels of Boeing’s Delta II, III & IV rockets
• Stringer structures in the pressure bulkheads of the Airbus A380/ A340
• Helicopter applications as main and tail rotor blades and fuselage panels
foam 1
foam 2
foam
3 50 mm
50 mm
350 mm 220 mm
Shearography on Rohacell material
adhesive
layers
26
shear
crack
dent in core
depth 10 mm
dent in core
depth 15 mm
release film
diam 5 mm conical hole
diam 4 - 1 mm
depth 60 mm
release film
diam 10 mm
Inhomogenity in
top skin
adhesive
layer 2
Inhomogenity
in top skin
Shearography on Rohacell material
13
![Page 14: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/14.jpg)
27
Composite Vessel Testing
• Composite pressure vessel
• Breathing tank demonstrator
• Type 4, 6,8 l
• Drop tests according to norm
EN12245:2002 (D)
• Loaded via internal pressure
• Sensor in pressure chamber
28
Composite Vessel Testing
• Defects found on all impacted areas
• Pressure variation for detection (0,5 Bar)
Impacts
• Analysis shows metric of defects
• Results transferable to other tank designs
14
![Page 15: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/15.jpg)
29
« Performing technical evaluation of
shearography to inspect sandwich
structures after assembly »
ISISmobile 3000 on thick sandwich
structures at Airbus in Toulouse
by courtesy of
Airbus Toulouse
Airbus Toulouse
30
Delamination
Delamination
Located unbonded honey
comb junction
Airbus Toulouse
15
![Page 16: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/16.jpg)
31
Sector 3
Sector 4 Sector 1
Sector 2
Field of
View
(FOV)
by courtesy of
Airbus Bremen
Airbus Bremen
Delaminations on
back side
32
Stringer delamination – difference of stiffness visible
Stringer delaminations – real defects
Delaminations
16
![Page 17: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/17.jpg)
33
Aircraft Engine Cover
One shot > 4 results
Thermal loading
Field of view: A4 paper size
outside
inside found with tap test
Delaminations
(not found by tab testing)
Delamination (confirmed
tab test result)
34
Detection of artificially induced
defects on backside with ISISmobile 3100
Impact
(7 mm depth with sphere 32 mm diameter)
Delamination: Top Layer - Core (25 mm diameter, depth 25 mm)
Delamination: Core - Rear Layer (30 mm diameter, depth 12 mm)
Aluminium Honeycomb
17
![Page 18: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/18.jpg)
35
Wing-Box NDT: Wrinkles
• NDI of wing box panel
• Wrinkles detected by Shearography
• Section analysis shows cut wrinkle details
36
Wing-Box NDT: Delaminations
• NDI of wing box panel
• Delaminations and linear anomalies detected by Shearography
• Section analysis shows delamination details
18
![Page 19: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/19.jpg)
37
Carbon Nomex Fuselage Material
• Fuselage material
• Artificially induced defects
• Defects displayed in right image
• Image below: side view of material
38
Shearography on helicopter tail rotor blade
• Helicopter tail rotor blade
• Artificially induced drillings
(50mm, 20mm, 10mm)
• Delams simulated
• Found defects displayed on the right side
Backside
19
![Page 20: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/20.jpg)
39
Vacuum excitation (∆ 40 mbar)
1: Delamination Top Layer – Core Impact
2: Impact
3: Delamination Core - Rear Layer
Unscaled result image Scaled result image
1
2
3 3
Aluminium Honeycomb
2
40
Scanning of complete spoiler
Detection of delaminations on
composite material
Comparison between ultrasonic
and shearography
Delaminations on Spoiler
20
![Page 21: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/21.jpg)
41
Automatic inclusion of results into
report and CAD data
Comparison of scanning time:
(complete spoiler scanned)
Ultrasonic approx. 1 hour
Shearography approx. 5 minutes
by courtesy of Airbus Bremen, Mr. Scherling
Delaminations on Spoiler
Inclusion of results
42
by courtesy of
GKN AEROSPACE GmbH
wrinkle
wave
Wrinkles
GKN – NDT on Wrinkles
21
![Page 22: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/22.jpg)
43
Inspection of wing section cut
Detection of delaminations
due to water inclusions
and cracks
Airbus Madrid – Cracks / Water Inclusions
by courtesy of Airbus
44
Damages due to water inclusions
Cracks detected
Airbus Madrid – Cracks / Water Inclusions
Amplitude comparison
of cracks
by courtesy of Airbus
22
![Page 23: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/23.jpg)
45
Kissing bond NDT
• NDT of a Kissing Bond
• CFRP top-layer foam core material
• First approach with demonstrator
material for in-field detection
• Artificially prepared with foil insert
before lamination
46
Kissing bond NDT
Kissing Bond
Impact defect
• Kissing Bond detected
• Thermal excitation (1s)
• Impact detected
• Result within 10s obtained
Kissing Bond is defined as a bonded area with
only 10% of mechanical properties
23
![Page 24: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/24.jpg)
47
Systems
48
First approach to NDT – ISIS1100
System for non-contact NDT:
• Portable System
• Flexible
• Easy to use
• On tripod
• Compact Electronic
• Adjustable to various tasks
• Easy upgradable
24
![Page 25: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/25.jpg)
49
ISIS 3100
ISIS 3010
Modularity of ISIS Systems
Electronic Unit
Sensors
50
Industrial solutions
ISIS 3100 ISIS 3010
AOI:
A4 Paper Size AOI:
A3 Paper Size
Exitation:
Heat & Vacuum Excitation:
Heat
Hood systems – Two Inspection Sizes
• Test large areas quickly
• Scan area & store image
• No calibration
• Reproducible results
• Macro function
• 1 click/ measurement
25
![Page 26: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/26.jpg)
51
Robot solutions
100 % Automation
fully contactless with thermal loading
Automatization
Stationary units (x,y,z axis rail)
52
Quanitative Mesurement
• From qualitative Testing…
…quantitative Evaluation • Numerical data export as csv
• Enables postprocessing in
xls, Mathlab, etc.
26
![Page 27: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/27.jpg)
53
Signal to noise ratio (SNR)
• Signal to noise ratio (SNR)
SNR
• Numerical values
• Direct comparison to UT
Signal
Noise dB values
• Indication of quality to NDT staff
54
Test plan NDT Test - Shearography
Documentation NDT Task One
Solution
100% Process chain
Sectors in test plan
Sectors on test Automatic reporting
Documentation process chain
27
![Page 28: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/28.jpg)
55
ISISmobile 3000 in operation at Airbus Hamburg
Successful Cooperation with the Industry
…for constant improvement of our products ISISmobile 3000 in operation at
Airbus Toulouse
56
References
28
![Page 29: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/29.jpg)
57
Summary
• Non-Contact analysis
• Fast inspection
• Full-Field results
• Ideal for composite materials
• Numeric data export
• SNR
• Production & maintenance
58
Shearography
Composite-NDT
Turbine Blade NDT in MRO
29
![Page 30: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/30.jpg)
59
Automated bisk measurements
Areas of use:
Blade designers
Blade manufacturers
Turbine manufacturers
Turbine & Blade MRO
60
Results:
3D point cloud
STL generation
Result to CAD fit
Detection of abrasion
Feature measurement
Length
Centre point
Angles
Radius
Automated bisk measurements
30
![Page 31: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/31.jpg)
61
Single Blade Digitizing
62
Single Blade Digitizing
Results:
3D point cloud
STL generation
Result to CAD fit
Detection of abrasion
Feature measurement
Length
Centre point
Angles
Radius
31
![Page 32: Shearography - New Possibilities in Composite Testing ...](https://reader031.fdocuments.us/reader031/viewer/2022012101/61db8d12f0aa872ba507224e/html5/thumbnails/32.jpg)
63
Automated Cell – Modular Concept
New approach:
Mobile modular measuring cell with L3D 5M Digitzing Senor
64
Thank you for your attention !
Do you have any questions ?
Author: Dipl. Wirtsch. Ing. - Raphael Schoen (International Sales Manager/ Shearography-NDT)
Contact: [email protected] ; +49 172 729 1583 ; www.steinbichler.de
32