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© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. New Standards. Together Presented by Keith Phillips / Head of NDT & Mechanical.

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Presentation on theme: "© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. New Standards. Together Presented by Keith Phillips / Head of NDT & Mechanical."— Presentation transcript:

1 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. New Standards. Together Presented by Keith Phillips / Head of NDT & Mechanical Testing - UK September 2013

2 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Contents Developments on Flexible UT Arrays to optimize curved surface testing Single Side Omega Stringer Integrity Check Advanced Simple to Use Quick Check Methods Line Tool DolphiCam Paint thickness measurement on CFRP Eddy Current with adapted probe (if LSP is present) Microwave for all cases Advanced new wheel probe for curved surfaces Fast CFRP-Nomex-Sandwich inspection with PAUT A4A Sept 2013Recent developments in NDT from Airbus Engineering

3 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Flexible UT Array to access narrow curved surfaces Objective: Optimised and improved capability for inspection of radius components Using a new flexible probe coupling technology combined with a linear transducer array based on a flexible foil with sensors A4A Sept 2013Recent developments in NDT from Airbus Engineering

4 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Flexible Array First 8 element flex array Next a 64 element flex array Finally coupling and housing are key elements in the design for easy handling A4A Sept 2013Recent developments in NDT from Airbus Engineering

5 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Flexible Array – Demo on Wing panel A4A Sept 2013Recent developments in NDT from Airbus Engineering

6 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Single Side Omega Stringer Integrity Check Objective: Fast inspection method to check a hidden and for direct NDT inaccessible structure part, which might be damaged with out any detectable/visible impact at the outer skin. Use of an advanced commercially available PAUT approach with an advanced PAUT system No need to know the exact position of the hidden structure A4A Sept 2013Recent developments in NDT from Airbus Engineering

7 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Single Side Omega Stringer Integrity Check A Conventional Single Transducer Approach A-Scan, Stringer with delamination A-Scan, Stringer no damage Conventional Transducers – it works but: awful to perform this inspection! A4A Sept 2013Recent developments in NDT from Airbus Engineering

8 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Different Array Approaches Optimized Aperture and Angle of Incidence Guided Wave approach to become independent from stringer position Most simple –perpendicular - approach A4A Sept 2013Recent developments in NDT from Airbus Engineering

9 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. PAUT – a simple direct inspection approach - B-Scan configuration with pitch/catch - Linear scanning with optimized angle of incident - 1 MHz probe in contact (water delay line possible) Indication of the UT signal travelling along the Omega-STRG 64 Elements 1 MHz probe A4A Sept 2013Recent developments in NDT from Airbus Engineering

10 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. PAUT – Approach with beam steering (Guided Wave) Sector-Scan configuration with pitch/catch, with beam steering from 0° - 80°. Combining a PAUT instrument and a 64 Element 1 MHz Probe with water box delay line for easy coupling. Use of Wheel probe to be checked later current wheels too narrow (wheel internal delay too big at current systems) A4A Sept 2013Recent developments in NDT from Airbus Engineering

11 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Advanced Simple to Use Quick Check Methods Line Tool (EADS IW (Innovation Works) ) for AIRBUS based on UT Array in a Wheel Probe Traffic Light Human Interface To be used by Non NDT mechanics Using wheel probe offering fast scanning DolphiCam (DolphiTech (N) & EADS IW / TESTIA support) 2D Array with volume scan capability Reduced and simplified controls Customized inspection APPs on Tablet PC Full A, B & C-Scan Display Dry coupling 30 x 30 mm field of view A4A Sept 2013Recent developments in NDT from Airbus Engineering

12 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Line Tool-Concept for Quick Damage Assessment A4A Sept 2013Recent developments in NDT from Airbus Engineering

13 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. DolphiCam – simple UT imaging method (2D) Full PAUT inspection system Simple user interface (APP-Style) Uses simple Tablet PC. Features dry coupling. Full A-,B-,C-scan, all volume data stored (if required) Gate to slice voxel data set Full post processing with NDT-Kit-Software (Airbus Standard) Fits with OMA (remote inspector) A4A Sept 2013Recent developments in NDT from Airbus Engineering

14 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. DolphiCam – simple UT imaging method (2D) DolphiCam uses a novel crossbar approach to excite moving sound fields for areal scanning 128 x 128 columns/rows can be switched generating an image 30 x 30 mm with ~16000 pixel 4.27 points/mm lateral resolution, recording a full A-scan (CFRP: now 8mm deep – 16 mm follows soon) A4A Sept 2013Recent developments in NDT from Airbus Engineering

15 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Paint thickness measurement on CFRP For metallic structures paint thickness measurement is a simple task: Just take Eddy Current and the lift/off effect. Or Ultrasound – as the acoustical impedance difference is high For CFRP the conductivity is extremely low, paint has similar acoustical impedance to resin, lot of paint layers give confusing echo pattern. How to proceed? Now 2 new successful solutions for a long unsolved task: Eddy current with large probe diameter if a copper lightning strike protection is present (the cheaper solution) Microwave, in all cases (only a little more costly) A4A Sept 2013Recent developments in NDT from Airbus Engineering

16 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Lightning strike protection by surface master An Expanded Copper Foil (ECF) dissipates the electrical energy in case of a lightning strike. It is a slit and expanded foil which forms as a net. External surface protection Pigmented resin with ECF CFRP Expanded Copper Foil (ECF) < limit ! Paint above ECF must not exceed a maximum thickness !! Must be checked! A4A Sept 2013Recent developments in NDT from Airbus Engineering

17 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Check of layer thickness above Expanded Copper Foil EDDY Current Thickness measuring works only on CFRP containing metallic LPS / ECF Typical Thickness Meter has a small ball pen sensor – result has a high inaccuracy dependig where you hit the surface: on top of a copper cross point or in the hole of the net Consequence: A large sensor diameter is the key to reliable measurement. A4A Sept 2013Recent developments in NDT from Airbus Engineering

18 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Check of layer thickness above Expanded Copper Foil Together with commercially available equipment suppliers an appropriate sensor was found, which fits to standard gauges: A 10mm diameter Sensor Result: It increased the accuracy by more than a magnitude The bigger sensor now integrates over a larger area with always a sufficient averaging of Copper and CFRP A4A Sept 2013Recent developments in NDT from Airbus Engineering

19 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Microwave for Paint Thickness measurement CFRP has a conductivity which rises with frequency. Carbon fibres itself are good conductors, resin is a dielectric medium in between, which lets the fibres act as a capacitor. This is for micro waves a perfect reflector having a very small penetration depth. Challenge: the fibres of the top layer reflect anisotropic Specific permittivity of different paint layers (Resin above the first layer of carbon fibres (or ECF LSP) adds to the measured thickness – but this does not matter if checking the LSP quality) Solution: An advanced and specific microwave antenna design and the well adapted detector unit, which is completely insensitive to permittivity changes and anisotropy (fiber orientation in surface layer) A4A Sept 2013Recent developments in NDT from Airbus Engineering

20 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. µ wave Paint thickness gauge for CFRP Microwave is applicable on ECF as well as on the CFRP substrate without ECF. A4A Sept 2013Recent developments in NDT from Airbus Engineering

21 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. µ-wave paint thickness gauge - accuracy Equipment suppliers realised a device with measurement results being independent of permittivity of (non-conductive) layer composition. Diagrams show measurement results of layers being partly paint and partly foils. A4A Sept 2013Recent developments in NDT from Airbus Engineering

22 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Advanced Wheel Probe for Large Area Inspection Portable device, quick and easy deployment rapid scanning of large areas of even thick CFRP structures New hand held approach with easier ergonomics for use under wing or other difficult areas - for vertical or overhead inspection Lighter: e.g. simple trolley design for lower weight – approx 1.9 kg For curved and geometrically challenging surfaces Fixed array height Simple guide wheels (could be rollers etc as required), wheel diameter ~ 35 mm, Wheel alignment flexible in scan and index axis, Flexible thin tyre A4A Sept 2013Recent developments in NDT from Airbus Engineering

23 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. New wheel probe – design challenges Different Normalization Tasks A4A Sept 2013Recent developments in NDT from Airbus Engineering

24 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. The new Airbus Wheel Probe A4A Sept 2013Recent developments in NDT from Airbus Engineering

25 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. General Procedure UT for Sandwich, NTM A - delamination between plies of outer CFRP skin B - disbond between outer skin and honeycomb core C - cracked honeycomb core D - crushed honeycomb core E - disbond between inner skin and honeycomb core F - fluid ingress in honeycomb core Its a kind of guided wave approach tuned to core height (membrane length = ½ λ) with equipment fulfilling specific needs: Square wave pulse excitation (preferred) good filter capabilities to tune the receiver Transducer runs best with tuned bandwidth: Debonding causes resonance shift to ¼ λ = octave down. Debonding echoes have > 6db less amplitude A4A Sept 2013Recent developments in NDT from Airbus Engineering

26 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document mm probe length (64 Elements) ~ 72 mm Scan (Index) - Axis 1. 5 mm Pitch Back wall echo (BE) Front surface echo (FSE) Wasservorlaufstrecke 1L64E96-22 Water Delay 1L64E96-22PHASED ARRAY – probe; 1MHz 64Elements (Array: 96mm x 22mm) Setting for linear electronic scanning for sandwich The linear scan is achieved by multiplexing of a single, constant Focal Law along a Linear-Array A4A Sept 2013Recent developments in NDT from Airbus Engineering

27 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. UT Array for CFRP-Nomex-Sandwich Inspection Method for single transducer to cover even non parallel areas using an average tilt angle – limited to non steep ramp structures - with PAUT also very steep ramp structures can be accessed A4A Sept 2013Recent developments in NDT from Airbus Engineering

28 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. UT Array for CFRP-Nomex-Sandwich Inspection A4A Sept 2013Recent developments in NDT from Airbus Engineering

29 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. UT Array for CFRP-Nomex-Sandwich Inspection Typical screen setup with TCG, Gates and B & C scan of de-bonded area Three areas of rear side disbond – C-scan & B scans Probe configurations: Direct contact Water box /water delay Wheel Probe (1MHz or 0.5 MHz necessary – not available yet) A4A Sept 2013Recent developments in NDT from Airbus Engineering

30 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Thank you for your time Any Questions? A4A Sept 2013Recent developments in NDT from Airbus Engineering

31 © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S.. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks. A4A Sept 2013Recent developments in NDT from Airbus Engineering


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