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Omniscan CFRP Radii Inspection Application Guide
Omniscan CFRP Radii Inspection Application Guide
COMPOSITE INSPECTION
CFRP Radii Inspection
Application Guide
Photo used with the permission of
Avior, Produits Intgrs
Radii Inspection Solution
OmniScan
MX
Curved Linear Array
Software Tools for Composite
Inspection
2
www.olympus-ims.com
The Company
Olympus NDT designs and manufactures ultra-
sonic and eddy current test systems for manual and
automated nondestructive testing. These systems are
used throughout the world for the analysis of defects
resulting from processes such as welding, extrusion,
and casting, as well as from wear, corrosion, and
fatigue.
The companys broad eld of activity includes aero-
space and automotive manufacturing, petrochemi-
cal industries, construction welding, and in-service
inspection.
To serve these markets, Olympus NDT has manufac-
turing facilities in the United States and Canada. The
company manufactures state-of-the-art, conventional
and phased-array ultrasonic equipment and probes
for the inspection of a wide range of tubes, plates,
welds, and composite structures.
Olympus NDT offers high-quality products and
services that have earned excellent reputations for
providing cost-effective solutions and excellent sup-
port and customer service.
Table of Contents
CFRP Radii Inspection Application Guide
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Basic Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Probe Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Setup Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radii Inspection Solution
OmniScan
MX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Phased Array Software Features . . . . . . . . . . . . . . . . 8
Software Tools for Composite Inspection . . . . . . . . . . . . . . . 9
Curved Array Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Immersion Corner Wedges for Curved Array Probes . . . . . 13
Options and Accessories
Custom Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mini Wheel Small Footprint Encoder . . . . . . . . . . . . . . . . 14
TomoView PC-Based Analysis Software . . . . . . . . . . . . . . 15
3
Introduction
Parts manufactured of carbon ber reinforced plastics (CFRP) pose an inspection challenge because of their many shapes and thickness-
es. Several parts in the aerospace industry consist of corners such as spars, stringers, and top-hat structures. Typical corner inspections
are performed in a manufacturing environment. Inspection of these corners is relatively new but is becoming more and more important
with the increasing usage of CFRP laminates in aircraft structures. Traditional inspections are performed manually with a conventional
ultrasonic probe. The slow and tedious nature of this inspection approach and the strong dependency on the inspector, are major disad-
vantages.
The OmniScan
PA uses appropriate probe holders and curved linear arrays composed of 16 to 64 elements that re in sequence to
cover the entire corner in a single pass. The inspection of the entire corner becomes an encoded one-line scan. The geometry of the
probe allows for all of the ultrasonic beams to coincide at 90 with the surface of the part in a manner similar to at surface inspections.
Furthermore, the unit provides multiple amplitude or time-of-ight C-scan mapping views that make data analysis an easy task. The
main advantages of using the OmniScan PA for this application, is the possibility of inspecting the entire corner in one simple scan. This
encoded data can then be used for sizing indications and defects. With respect to inspection speed, a typical setup can inspect along a
corner at up to 200mm/s.
This radius inspection solution is based on:
OmniScan MX instrument
OmniScan MXU software
- Familiar menu-driven interface
- Multiple C-scan option
- A-Scan and C-scan data storage
- TCG
- One-button switching between PA and UT
- Customizable color palette for amplitude and thickness C-scans
- Live A-scan and B-scan
Curved PA probes
- Acoustic impedance matched with water
- High circumferential resolution around the radius
- Corrosion-resistant stainless steel case
- Waterproof guaranteed to 1 m (3.28 ft)
- Compatible with adjustable immersion wedges
Immersion corner wedges for curved array probes
- Available in specic radius and angle
- Adjustable radius to t on various components to be inspected
- Designed to perform manual scans with a Mini Wheel
encoder, or a
time base
4
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Basic Concepts
Phased array technology is a nondestructive technique that enables the genera-
tion of an ultrasonic beam where parameters such as angle, focal distance, and
focal point size are controlled through software. Furthermore, this beam can
be multiplexed over a large array. In composite inspection, a 0 electronic scan
is performed through successive ring of the elements. When no time delay is
applied to the elements, the PA probe res a 0 beam and does not apply any
steering or focusing.
There are a multitude of benets associated with using phased array ultrasound
for inspecting at and corner-shaped composite parts. Notably, the enhanced
data imaging reduces the human-error factor. Likewise, the use of C-scan
imaging increases the reliability of the inspection because it guarantees the full
coverage of the inspected surface. Also, the large multielement probes increase
inspection speed and resolution. With the use of an appropriate scanner, radii
can be inspected in one pass, while a linear encoder assists in defect position-
ing and sizing. As well, future analysis and periodic comparisons can be done
because the A-scan and C-scan data is stored.
Furthermore, the OmniScan
PA al-
lows A-scans to be synchronized to an interface gate
(I), which gives exibility to the probe position with
respect to the radius. The A and B data gates as well
as the TCG correction, are all synchronized to the
interface gate.
TWO OR THREE GATES (I, A, B)
Gate I can be used to synchronize the other 2
gates on the front wall.
Gate A typically begins right after the front wall
and continues past the back wall. This gate is
used to produce amplitude and time-of-ight
(TOF) C-scans.
Gate B is typically employed to monitor back-
wall amplitude when the panel has a relatively
constant thickness.
C-SCAN DISPLAYS (A%, TOF, B%)
Depending on the sample and the defects, each
display has its merits and inconveniences.
TIME-CORRECTED GAIN (TCG)
To obtain 80% front-wall and back-wall echoes.
Data Analysis
The main differences between inspecting the corners
in this way and inspecting a at panel are:
The correlation required for index sizing on the
corners.
The beam inversion for ID inspections
INDEX SIZING ON THE CORNERS
Indication sizing in the scan direction can be di-
rectly measured from the encoded readings and the
displays on the OmniScan. In the index direction, a
geometric conversion taking into account the radius
of the phased array probe (R), the radius of the corner
(r), the depth of the indication (d), the thickness of
the part (T) and the indication size as displayed on
the OmniScan (S), is required to obtain the actual
indication size (s). This conversion is also dependant
on the type of inspection (ID or OD).
BEAM INVERSION FOR ID INSPECTION
When performing an inspection from the inside
diameter (ID), the beam created from the rst ele-
ments of the probe reects on the highest part of the
corner (beam 1), whereas the beam created from the
last elements reects on the bottom part of the corner
(beam 8). Therefore, the beams are inverted on the
S-scan display as well as on the C-scan.
Display showing A-scan, S-
scan, and TOF C-scan
Display showing A-scan, ampli-
tude C-scan, and TOF C-scan
Display showing A-scan, S-scan, and ampli-
tude C-scan
Due to the beam inversion phenomenom the beams are
inverted on the C-scan.
7
OmniScan 16:128 phased array module offers live switching from
phased array mode to conventional UT mode for quick verication
and defect sizing useful for certain code requirement applications.
OmniScan
MX
With hundreds of units being used throughout the
world, the OmniScan
Windows
card).
Complete report setups, including reading
congurations, that can be customized using
HTML page layouts.
Easy report generation; from acquired data to
complete report in seconds
On-screen interactive help that can be
customized for procedure-oriented setups using
HTML script templates
Setup preview
Predened setups
CONNECTIVITY, DATA STORAGE, AND
IMAGING
The OmniScan
in
order to provide the correct thickness measurement. The Min. and
Max. values are used to set up the color palette scale. By default,
everything below the minimum value is colored red and every-
thing above the maximum is colored blue.
Display showing the effect of setting
the maximum thickness value. On the
left, the Max. is set to 50mm; on the
right the Max is set to 5.5mm.
Measurements > Thickness > Source = A/ - I/
Measurements > Thickness > Min. = 0.05
Measurements > Thickness > Max. = 50
HOW TO SET THE MINIMUM RANGE
Composite materials can be manufactured in a wide range of
thicknesses. When inspecting thin parts, it is often necessary to re-
duce the range to analyze the area of interest. The range is directly
proportional to the number of points recorded on each single A-
scan. By default, the points quantity is set to 320. For example, in
a material with a velocity of 3000m/s and without compression,
the minimum range permitted by the OmniScan is 4.80mm. It is
also possible to reduce that range to 0.48mm by directly editing
the minimum number of points quantity on the OmniScan to 32.
UT Settings > Advanced > Points Qty. = 32
UT Settings > General > Range = edit or scroll
with the knob
Display showing the effect of setting
the point quantity on the range value.
On the left, the number of points is
set to 320; on the right the number is
set to 160.
DISPLAY WITH AUTOMATIC DATA CURSOR SELECTION
When in the phased array conguration, the user must select, with
the data cursor, the A-scan he wants to display. The OmniScan
can automatically display the A-scan with:
The highest signal in gate A
The minimum thickness value in gate A
Note that layouts containing a B-scan cannot be displayed when
using either of these two modes.
11
Display > Properties > Scan = A-Scan
Display > Properties > Source = Highest (%)
Display > Properties > Source = Thinnest
LAYOUT: ABS
The ABS layout offers an A-scan, B-scan, and S-scan to be viewed
all at the same time while in acquisition or setup mode. Further-
more, once the acquisition is complete and the OmniScan has
been switched to analysis mode, this layout adds the C-scan view
in order to facilitate quick and easy analysis.
Display > Selection > Display = A-B-S
READING I(W)/
This reading displays the water column between the probe and
the part.
Measurements > Reading > Field x
(1, 2, 3, or 4)= I(w)/
C-SCAN ANALYSIS READINGS LIST
A predened group of reading elds has been selected in order to
facilitate the analysis.
A%: amplitude of the signal in the gate
S(m-r): distance on the scan axis obtained by subtracting
the position of the reference cursor from the position of the
measurement cursor
I(m-r): distance on the index axis obtained by subtracting
the position of the reference cursor from the position of the
measurement cursor
T(A/-I/): thickness measurement
Measurements > Reading > Group =
C-scan Analysis
12
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R
A
R casing
Curved Array Probes
3.5CC25-32-R4 3.5CC10.2-16-R1 3.5CC50-64-R5
As a world leader in PA probe manufacturing, Olympus NDT has once
again proved its superior applications knowledge with the introduction
of the Curved Array Probe series. Every aspect of the probes has been
examined and optimized for more inspection possibilities and a more
ergonomic design.
Advantages
Acoustic impedance matched with water
High circumferential resolution around the radius
Corrosion-resistant stainless steel case
Waterproof guaranteed to 1 m (3.28 ft)
Compatible with adjustable immersion wedges (shown on page 13)
Probe Specications and Dimensions
Part number
Casing
type
Frequency
(MHz)
Number of
element
Pitch (mm)
Elevation
(mm)
Radius
(mm) (R)
Angle ()
(A)
Inspection
type
Minimum part
opening angle ()
3.5CC10.2-16-R1 R1 3.5 16 1.0 5.0 10.2 90 ID 70
5CC10.2-16-R1 R1 5.0 16 1.0 5.0 10.2 90 ID 70
3.5CC25-32-R4 R4 3.5 32 1.32 6.0 25.0 90 ID, OD 70
5CC25-32-R4 R4 5.0 32 1.32 6.0 25.0 90 ID, OD 70
3.5CC50-64-R5 R5 3.5 64 1.65 6.0 50.0 121 OD 50
5CC50-64-R5 R5 5.0 64 1.65 6.0 50.0 121 OD 50
These probes come standard with an OmniScan
connector and a 2.5 m (8.2 ft) cable, or can be specially tted with other connectors and cable lengths.
Choosing the appropriate probe depends on the geometry of the
part. The main factors that need to be considered are the inspec-
tion type (ID or OD), the radius of the corner, and the angle of the
corner. Once the choice of probes has been narrowed, the thick-
ness of the part as well as the footprint of the probe and wedge
must be taken into consideration. The following steps should be
used as a guideline:
Step 1: Choose the appropriate probes that match the inspection
type, radius and angle of the corner to be inspected. (This is espe-
cially important for ID inspections where the minimum radius that
can be inspected is determined by the angle of the corner.)
Step 2: Validate whether these probes are compatible with the
maximum thickness of the part.
Step 3: Ensure that the size of the probe is conducive to the part
geometry. Care must be taken with H beams to ensure that the
probe and wedge are small enough to t in between the anges.
For more information contact an Olympus representative.
Choosing the appropriate curved array probe
13
SR1-I81-ADJ SR4-IE90-ADJ
Available for specic radius and angle, and a radius adjustment to t various components
Designed to perform manual scans
Designed to be used with the Mini Wheel
encoder
Immersion Corner Wedges for Curved Array Probes
GLOSSARY USED TO ORDER WEDGES
Wedge type
SR1 = wedge for curved probe type R1
SR4 = wedge for curved probe type R4
SR5 = wedge for curved probe type R5
Inspection type
I = internal
E = external
Angle of inspected part ()
81 = 81
90 = 90
98 = 98
Custom angles can be ordered.
Radius
Radius in in.
ADJ = adjustable radius
Wedge type
Inspection type
NUMBERING SYSTEM USED TO ORDER WEDGES FOR CURVED ARRAY PROBES
SR1-I90-0.125
Radius
Angle of inspected part
Wedge Specications
Part number Probe type Angle of the inspected part () Radius range in mm (in.) Inspection type
SR1-I81-ADJ R1 81 4 to 14 (0.157 to 0.551) ID
SR1-I90-ADJ R1 90 3 to 14 (0.118 to 0.551) ID
SR1-I98-ADJ R1 98 3 to 13 (0.118 to 0.512) ID
SR4-IE90-ADJ R4 90 3 to 20 (0.118 to 0.787) ID, OD
14
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Mini Wheel Small Footprint Encoder
The Mini Wheel
instrument
BX version compatible with the TomoScan FOCUS LT
instrument
Options and Accessories
Custom Wedges
REQUIRED INFORMATION FOR CUSTOM WEDGE ORDERS
When ordering custom wedges that are not listed, the following information must
be provided:
1. Part geometry (such as: I-beam, L, Z frame)
2. Preferred inspection approach: ID or OD
3. Probe casing type: R1, R4, or R5.
4. Fixed or variable radius
5. Part opening angle ()
6. Corner inner radius (provide maximum and minimum radii if variable wedge
is requested)
7. Maximum part thickness in the radius
1
6
5
15
Reference area dened by the
contour cursors (pink)
Reference area between the refer-
ence and measurement cursors
Binary image based
on the SNR values
Raw image Binary image
Reference Area Information
Displays mean value (Amplitude or Depth) and
standard deviation value of reference area.
Histogram Distribution
Counts the percentage of pixels of each color level
between 0% and 100% and displays the results as
a graph (represents the region dened between the
reference (red) and measure (blue) cursors).
Computed Indication Area
Measures the size of the area being above the Sig-
nal/Noise value (signal/noise value can be adjusted
using the K value).
Excludes values below gate amplitude threshold
from histogram and defect area.
TomoView PC-Based Analysis Software
OmniScan
scanner and probes dedicated to CFRP at
panel inspection.
The CFRP Flat Panel Inspection Solution
from Olympus provides a portable solu-
tion with advanced tools such as two axes
encoded C-scans with amplitude and time-
of-ight (TOF) information, gate synchro-
nization, and data recording. The GLIDER
scanner is easy to use and well-suited for
raster scanning with both conventional UT
and phased array probes. The Olympus
CFRP solution offers important benets:
High inspection speed
Powerful and versatile software tools
Ease of deployment
Greater POD
Portability
Note:
The Olympus CFRP Flat Panel Inspection
Solution can also be used for other FRP
at panels.
920-166A-EN
OMNISCAN SOLUTION
CFRP Flat Panel Inspection
Conventional UT and Phased Array
Inspection Solution
FEATURES
OmniScan instrumentation
OmniScan software
- Familiar menu-driven interface
- Multiple C-scans option
- A-Scan and C-scan data storage
- TCG
- Quick swapping between PA and UT
for prove up and defect sizing
- Customizable color palette for
amplitude and thickness C-scan
GLIDER scanner
- Well suited for PA, UT, ECA, and EC
probes
- High inspection speed
- Two encoded axes
UT and PA probes and wedges
- Near-wall probes: shortened dead
zone at both ends
- Delay line: provides excellent near-
surface resolution
- Water Pocket Rexolite
wedge: for
limited irrigation needs and better
coupling on some surfaces
Your Challenge
Shinjuku Monilith, 3-1Nishi-Shinjuku2-chome, Shinjuku-ku, Tokyo 163-0914,
Japan, Tel: 81(0)3-6901-4039
48 Woerd Avenue, Waltham, MA 02453, USA, Tel.: (1) 781-419-3900
Stock Road, Southend-on-Sea, Essex, SS2 5QH, UK, Tel.: (44) (0) 1702 616333
450 Campbell St. Unit 5, Cobourg, Ontario K9A 4C4, Tel.: (1) 905-377-9611
31 Gilby Road, Mount Waverly, Victoria, 3149, Tel.: (61) 130-013-2992
Valley Point Offce Tower, 248373, Tel: (65) 68-34-00-10
CFRP Radii_Application_Guide_EN_200908 Printed in Canada Copyright 2009 by Olympus NDT.
*All specifcations are subject to change without notice. All brands are trademarks or registered trademarks of their respective owners.
is ISO 9001 certifed.
www.olympus-ims.com
info@olympusNDT.com
CFRP Flat Panel Inspection Solution
Parts manufactured from laminate composite materials pose an inspection challenge because of their many shapes and thicknesses. How-
ever, many parts consist of a somewhat at section such as skins, stringers, and spars. Olympus offers a complete solution for the inspec-
tion of carbon ber reinforced plastic at panels. This solution is based on the OmniScan