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New Standards. Together

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Presentation on theme: "New Standards. Together"— Presentation transcript:

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

2 Recent developments in NDT from Airbus Engineering
A4A Sept 2013 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

3 Flexible UT Array to access narrow curved surfaces
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

4 Flexible Array First 8 element flex array Next a 64 element flex array
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

5 Flexible Array – Demo on Wing panel
Recent developments in NDT from Airbus Engineering A4A Sept 2013 Flexible Array – Demo on Wing panel

6 Single Side Omega Stringer Integrity Check
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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 Remark: currently we could only realize this method with the Sonotron Isonic 2009 PAUT system, Software limitations of systems like OMNISCAN prevent the necessary independent control of two freely and independently selectable & controllable groups in one array. Also the human interface of the ISONIC 2009 turned out to be outstanding for a fast and easy setup.

7 Recent developments in NDT from Airbus Engineering
A4A Sept 2013 Single Side Omega Stringer Integrity Check A Conventional Single Transducer Approach A-Scan, Stringer no damage A-Scan, Stringer with delamination Conventional Transducers – it works but: awful to perform this inspection!

8 Different Array Approaches
Recent developments in NDT from Airbus Engineering A4A Sept 2013 Different Array Approaches Most simple –perpendicular - approach Optimized Aperture and Angle of Incidence Guided Wave approach to become independent from stringer position

9 PAUT – a simple direct inspection approach
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

10 PAUT – Approach with beam steering (Guided Wave)
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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)

11 Advanced Simple to Use Quick Check Methods
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

12 Line Tool-Concept for Quick Damage Assessment
Recent developments in NDT from Airbus Engineering A4A Sept 2013 Line Tool-Concept for Quick Damage Assessment

13 DolphiCam – simple UT imaging method (2D)
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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)

14 DolphiCam – simple UT imaging method (2D)
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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)

15 Paint thickness measurement on CFRP
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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)

16 Lightning strike protection by surface master
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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 < limit ! Pigmented resin with ECF CFRP Expanded Copper Foil (ECF) Paint above ECF must not exceed a maximum thickness !! Must be checked!

17 Check of layer thickness above Expanded Copper Foil
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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.

18 Check of layer thickness above Expanded Copper Foil
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

19 Microwave for Paint Thickness measurement
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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)

20 µ wave Paint thickness gauge for CFRP
Recent developments in NDT from Airbus Engineering A4A Sept 2013 µ wave Paint thickness gauge for CFRP Microwave is applicable on ECF as well as on the CFRP substrate without ECF.

21 µ-wave paint thickness gauge - accuracy
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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.

22 Advanced Wheel Probe for Large Area Inspection
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

23 New wheel probe – design challenges
Recent developments in NDT from Airbus Engineering A4A Sept 2013 New wheel probe – design challenges Different Normalization Tasks

24 The new Airbus Wheel Probe
Recent developments in NDT from Airbus Engineering A4A Sept 2013 The new Airbus Wheel Probe

25 General Procedure UT for Sandwich, NTM 51-10-24
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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 It’s 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

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

27 UT Array for CFRP-Nomex-Sandwich Inspection
Recent developments in NDT from Airbus Engineering A4A Sept 2013 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

28 UT Array for CFRP-Nomex-Sandwich Inspection
Recent developments in NDT from Airbus Engineering A4A Sept 2013 UT Array for CFRP-Nomex-Sandwich Inspection

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

30 Thank you for your time Any Questions?
Recent developments in NDT from Airbus Engineering A4A Sept 2013 Thank you for your time Any Questions?

31 Recent developments in NDT from Airbus Engineering
A4A Sept 2013 © 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.


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