CSERIES In-Service Non-Destruction Inspection of Composite Components

Noticeably, in the past decade, there has been a significant increase in the use of carbon fiber reinforced plastic (CFRP) composite materials in aircraft design of primary structures mainly due to the requirements to reduce... [ view full abstract ]

Noticeably, in the past decade, there has been a significant increase in the use of carbon fiber reinforced plastic (CFRP) composite materials in aircraft design of primary structures mainly due to the requirements to reduce manufacturing costs and weight. The composite structures are both monolithic and honeycomb sandwich configurations.
Unlike metallic structures, composites are much more susceptible and less forgiving to operational damage such as accidental impact events and environmental factors. If these damages go undetected it can severely reduce the overall strength of the components and functionality and potentially, lead to premature failures.
As composite material properties, characteristics and discontinuities differ from traditional metallic structures, new advanced non-destructive inspection methods and techniques are also required.
Potential in-service defects include but are not limited to; Accidental Impact Damages (AID) resulting in delamination between interplies, crushed core, disbonds between Core and Laminate (Skins) and Laminate-to-Laminate (Co-bonded). Environmental damage includes water ingress and lightning strike as well as excessive heat exposure over cure temperature.
A generic Calibration Reference Standard (CRS) design is required for ultrasonic inspection equipment calibration and time corrected gain (TCG) set-up. The purpose of the CRS design is to cover all monolithic CFRP components up to one inch in thickness regardless of surface finish i.e. NCF, different CF grades, and surface coatings.
Local, large and widespread damage NDI methods and techniques will be presented. Some of the methods and techniques discussed will include conventional manual ultrasonic with A-scan data presentation, UT phased array A, B, and C-Scan presentations with 2-axis scanners, bond testing, radiography inspection techniques, shearography, infrared thermography etc.