Types of NDT

Non-Destructive Testing (NDT)

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Visual Ultrasonic X-ray Thermographic Acoustic Emission Eddy Current Shearography

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Visual Inspection
Basic principle: illuminate the test specimen with light examine the specimen with the eye Used to: to magnify defects which can not be detected by the unaided eye to assist in the inspection of defects to permit visual checks of areas not accessible to unaided eye Most widely used of all the nondestructive tests. Simple, easy to apply, quickly carried out and usually low in cost.
ENG 4793: Composite Materials and Processes

Visual Inspection Equipment

Magnifying Glass Magnifying Mirror Microscope Borescope
endoscopes or endoprobes

Flexible Fiber Optic Borescope

working lengths are normally 60 to 365 cm with diameters from 3 to 12.5 mm

Video Imagescope
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ENG 4793: Composite Materials and Processes

Borescopes

Ultrasonic Testing
The use of ultrasonic waves to evaluate the condition of a material. Anomalies absorb or deflect the sound waves, which are then detected as changes in the waves.

Rigid

Flexible fiber optic

holes, delaminations, voids damage, debonds resin-rich, -poor areas

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ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Through Transmission Mode

Reflected (pulse-echo) Transmission Mode

emitter part part

emitter - detector - transceiver

reflector detector

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

Ultrasonic Test Equipment C-scan

A-scan (single pulse - ice pick)

Received pulse amplitude is represented as a displacement along one axis and the travel time of the ultrasonic pulse is represented as a displacement along the other axis. A-scan displays are more complex because all reflections are displayed, so signals (back wall, waterpath) need careful interpretation.

ENG 4793: Composite Materials and Processes

ENG 4793: Composite Materials and Processes

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A-scan

B-scan (cross section)

A two-dimensional graphical presentation, in rectangular coordinates, in which the travel time of an ultrasonic pulse is represented as a displacement along one axis, and transducer movement is represented as a displacement along the other axis.

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B-scan

C-scan (defect location map)

A two-dimensional graphical presentation, in which the discontinuity echoes are displayed in a top view on the test surface. This method is applied to pulse-echo and through transmission techniques. Usually no indication of depth is given unless the complete scan represents the time of flight evaluation (D-scan).

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C-scan

C-scans

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3D C-scan

C-scan test block

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D-scan (defect depth map)

A two-dimensional graphical presentation, in which the time-of-flight values are displayed in a top view on the test surface. This is a modified Cscan in which are amplitudes displayed.

D-scan

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D-scan of Test Block

Performance
5-25 MHz typical 0.2- 800 MHz possible Trade-off between frequency (resolution) and depth of penetration
higher frequency, better resolution, lower depth of penetration

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X-ray Technique

Microfocus X-ray Technique

Film pack or X-ray imaging system X-ray source Test object Test object Microfocus X-ray source

Film pack or X-ray imaging system Greatly enlarged image

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Microfocus X-ray Equipment

Real Time X-ray Technique

Fluorescent screen TV camera Monitor scope

X-ray source

Intensifier Test object

Image processor

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X-ray Images

X-ray Images

IC chip

Computer mouse

Cooling lines in turbine blade Porosity in weld

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CT Scan
CT produces 3-dimensional images of objects using x-rays. The scanner, made in the shape of a ring, contains an x-ray tube that circles the object. The object in the scanner is bombarded by xrays from various angles and resulting information signals are then processed by a computer, yielding cross sectional slices which then make up images.
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CT Scanner

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CT Scan Images

Restrictions
Radio opaque penetrant sometimes needed, as many composites are transparent even to low energy X-rays 15 - 25 kV
zinc iodide tetrabromoethane diiodobutane

Cannot detect fiber breaks

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Thermographic Principle
Heat flow in a material is altered by the presence of some types of anomalies. These changes in heat flow cause localized temperature differences in the material. Slow heating of part reveals these anomalies.

Thermographic Technique

Heat source

Part

IR camera

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Thermography Images

Acoustic Emission Principle

Sounds made by a material, structure, or machine in use or under load are heard and analyzed to determine its "state of health". One or more ultrasonic microphones are attached to the object and the sounds are analyzed using computer based instruments. Noises may arise from:

PC board Aircraft wing

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friction (including bearing wear) crack growth material changes (such as corrosion)
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Acoustic Emission Technique

Acoustic Emission Set-up

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Acoustic Emission Advantages

Entire structure can be monitored from a few locations. Structure can be tested in use. Continuous monitoring with alarms is possible. Microscopic changes can be detected if sufficient energy is released. Source location is also possible using multiple sensors.
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Acoustic Emission Applications

pipelines storage tanks (above and below the ground) fiberglass structures rotating machinery weld monitoring biological and chemical changes

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Eddy Current Principle

When an energized coil is brought near to the surface of a metal or conducting component, eddy currents are induced into the specimen. These currents set-up magnetic field that tend to oppose the original magnetic field. The impedance of coil in close proximity to the specimen is affected by the presence of the induced eddy currents in the specimen. When the eddy currents in the specimen are distorted by the presence of the flaws or material variations, the impedance in the coil is altered. This change is measured and displayed in a manner that indicates the type of flaw or material condition.
ENG 4793: Composite Materials and Processes

Eddy Current Technique

Eddy current field Probe

Defect

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Eddy Current Applications

Range from crack detection, to the rapid sorting of small components for either flaws, size variations, or material variation. Commonly used in aerospace, automotive, marine, and manufacturing industries.

Shearography
The object under study is illuminated by laser light, and a camera produces two sheared images that interfere with each other, causing a speckle pattern. When the object is deformed (sheared), the speckle pattern changes. The two speckle patterns interfere to produce a fringe pattern that depicts the surface gradient of the deformed object. Though the images obtained are good, this method is time-consuming.

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Shearography Technique

Shearography Images

Laser Part

Shearography head and detector

Shear motion Debonds

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Summary
Optical and Ultrasonic most widely used techniques. Each has different principles and uses.

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