NDE-NDT Technologies

BTG Composites Inc.
2010
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An Unforgiving Business;
One Strike and You’re Out
Titan IV A-20 Delta III

Photographs courtesy of U.S. Air Force.
BTG Composites Inc. 2010
2
Over $11 Billion
in Lost Space Assets in 1990s
Military, Civil + Commercial Satellite / Launch Failures
3
3 Titan IVs
2.5 NRO/DSP/Milstar
2 Delta IIIs
Mars Climate Orbiter
2 Landsat 6, NOAA 13,
$B Mars Polar Lander
UFO-1
1.5 Mars Observer
0.5
0
90 91 92 93 94 95 96 97 98 99
Fiscal Year
Graph courtesy of W. Tosney; Proceedings of the 4th International Symposium on
Environmental Testing for Space Programmes, June 2001.
3
Composite Tanks
1990
NASP,
1995 1998
Lobed X-33, Lobed
DC-XA
NGLT
2001 Reusable
X-34 Pathfinder NGLT Composite
Conformal Composite
Decades of technical development provide a strong

technology base for launch vehicle development.
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Why NDT? Is There a Reason?
y NDT ‐ non‐destructive testing
y Goal is to find potential defects/anomalies that may
affect composite performance:
y Inhomogeneities within the materials
y Fiber breakage
y Resin micro‐cracking
y Voids and porosity
y Degradation areas, impact damage
y Delaminations and separations
y Cure deficiencies
6
NDT vs. Testing and Analysis
y Non‐destructive Testing (NDT)
y Locates potential problem areas
y Testing and Analysis
y Required to define problem extent
y Destructive testing often performed
y Analysis might aid in minimizing testing
y Usually both are required
y Accept‐Reject Criteria important !
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Typical NDE Techniques
y Visual Inspection
y Tap Testing
y Ultrasonic Methods
y X‐Ray & Neutron Radiography
y Thermography
y Shearography & Interferometry
y Acoustic Emission (AE)
y Eddy Current & Dye Penetrant
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Visual Inspection
y Easiest system to use (eye, microscope)
y Can visually detect:
y Surface damage, abrasions, cuts, dents, gouges and
scratches (qualitative assessments)
y Burn or scorching
y Blisters, bubbles on surface
y Porosity, delaminations (edges)
y Some limitations ‐ first line of investigation
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How Do We Detect Damage ?
The first method of

detection particularly on the
flight line is often visual.
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Battle Damage
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Jackstands
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Bird Strikes
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Tap Testing
y Follow‐on to visual in many cases
y Effective in mapping delamination areas
y Inexpensive ‐‐‐ uses 25‐cent piece
y Thin composites easier
y Composites ‐‐‐ YES; cores ‐‐‐ NO
y Based on ability to `hear’ sound differences
y Used extensively because of ease and cost
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Coin Tap Testing (Inexpensive)
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Tap Testing Is Typical First Step
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Ultrasonic Test Methods
y Several `sound wave’ methods inherent:
y Ultrasonic through‐transmission testing
y Ultrasonic pulse echo testing
y Ultrasonic polar backscatter(*)
y Ultrasonic resonance (*)
y Ultrasonic correlation (*)
(*) Not covered here ‐‐‐ additional techniques used in
advanced composites today
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Through‐Transmission Ultrasonic
Testing
y Access to both sides of composite structure
y Called “C‐Scan” inspection display
y Must utilize `coupling’ agent on surfaces
y Sound waves (> 20kHz) pass through composite thickness
y Most commonly used technique:
y Delaminations
y Voids and porosity
y Fiber/matrix damage
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Manufacturing & Inspection Technology
y Large Filament Wound
Rocket Motor Case
y AS4/HBRF‐55A and AS4/3501‐6
technology
y 146 in. diameter
y Thick‐wall structure (2 in. max.)
y Filament winding with prepreg
joint broadgoods interspersed
y Pinned composite/metal joints
y Through‐thickness ultrasonic
inspection process
y 1.4‐2.0 safety factors
y A‐basis design allowables
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Pulse‐Echo Ultrasonic Testing
y Access from only one side of composite
y Called “A‐Scan” inspection display
y More applicable to field inspections
y Same anomalies as Through‐Transmission
y Commonly used technique in field
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Composite Plate (Ballistic)
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“Kissing Unbonds” Difficult to Locate
and Assess
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Impact Damage (left) and Mold
Released (right)
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Tap Test NDT Scans Limited
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Laser Pulsed‐Ultrasonic Image
Inspection Method
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X‐Ray Inspection
y Technique in use many years
y Nozzles
y Rocket motors (case, propellant, bondlines)
y Heavy equipment ‐‐‐limited mobility
y More accessible equipment now available
y Detects density changes
y Picks up (voids, porosity, delaminations)
y Bonded interfaces easiest
y Water and inclusions detected
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Radiation Source
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Radiographic Detector
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ERESCO 42 MF
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Super Alloy Bucket Fenning at 400kv, 0.5 Inch Inconel
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Airforce Radiographic Inspection for
Crack Detection
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Sharpness With FD Aging Air Application
(Crack Detection)
Film Digitization of a Tab from a 44% Spar on Left Wing Box (Wing Station
101) On a T-38 with D5 Film at 100µm, and 50µm:
100µm FD: 50µm FD:
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X‐Ray Technique for Solid Rocket
Motors Look at Bondlines
y Motor cases are
typical epoxy resin
with glass, carbon, or
Aramid fibers
y Interior has rubber
insulation and solid
propellant (like
rubber eraser
material)
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Neutron Radiography
y Equipment limited technique (size, cost)
y Power requirement problems
y Moisture detected easily
y Neutron rays are lethal
y Neutron density technique
y Potential for composites (in development)
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Thermography
y Uses heat transfer ‐‐‐ not sound waves
y Infrared technology basis
y Requires infrared video camera
y Measures effects from thermal changes
y Finds contamination (moisture, solvents)
y Pulsed thermography newest technique
y Potential field usage (infrastructure, honeycomb
structures, unbond regions)
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Typical Thermographic Image
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Flash‐Thermographic Imaging
y Left photo ‐‐‐ very thin adhesive fillet formation
y Right photo ‐‐‐ thicker grid indicates better
adhesive fillets in honeycomb cells
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Shearography & Interferometry
y Uses laser imaging systems
y Holography/interferometry vibration sensitive to
surrounding environment
y Shearography not as sensitive to vibrations
y Good degree of success more recently:
y Honeycomb bonded structures
y Sandwich panel sections
y Achieving much better reliability now
39
Acoustic Emission (AE) Testing
y Requires that part be loaded or stressed
y Listens to sound generation:
y Fibers breaking
y Delaminations
y Resin cracking
y Fixture, fittings noise (e.g. friction effects)
y Needs extensive data base for assessment
y Cannot separate various mechanisms
y Moderate acceptance (pressure vessels)
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Acoustic Emission Testing
y 36‐inch diameter
composite pressure
vessel used for damage
assessment
y Acoustic emission used
to assess defect growth
y Require 3 AE sensors to
triangulate defect
growth & affects
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Impact Damage Point
y Impact damage to
composites affect
structural
performance
y Visual damage often
only means of quick
detection
y Ultrasonic follow‐up
critical to structural
assessment
42
Thickwall Composites Pose Unique NDT
Problems
y Thickwall composites
mean potential
problems:
y Delaminations
y Porosity & voids
y Cut fibers
y Gaps between tows or
rovings
y Uncured areas
y Bolt holes
43
Close‐up of AE Sensors
y AE sensors mounted on
filament wound
composite case
y Sensors mounted on
outside of case
y Requires reliable data
base in order to assess
effect of any types of
damage or defects
44
AE Cycles Required to Establish
Damage Progression
y AE “hold”
periods aid
determination
of damage
threshold
y AE load steps
used to assess
initiation points
45
AE Signals Require Definition
y AE useful tool – but
requires good data
base
y “Hold” duration used
to assess damage
internally
y Cannot establish
mode (fiber, resin,
void – growth or
fracture)
46
Pressure Vessel Burst Related to AE
Events & Damage
y 20‐inch diameter
carbon fiber/epoxy
pressure vessels
y Filament wound
y Impact damage with
metal impact head
y AE shows “trend” but
not always very
definitive or
inexpensive to obtain
data
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Eddy Current
y Rely on magnetic material properties
y Glass fiber composites ‐‐‐ NO
y Carbon fiber composites ‐‐‐ MAYBE
y Fiber orientation
y Fiber breakage
y Impact damage and fatigue
y Poor industry acceptance to date !
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Most Likely Used NDT Methods
y Visual inspection (first quick look)
y Tap testing (rough out damage area)
y Ultrasonic test methods
y Through transmission
y Pulse echo from one side
y Thermography (honeycomb and core structures)
y Shearography methods
y Some X‐ray and computed tomography (CT)
applications
49
Least Likely Used NDT Methods
y Eddy current
y Dye Penetrant (metals mostly)
y Acoustic emission (depends on application and available
data base) – ASTM Codes often require AE technique
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NDT Requires Known Defect “Standard”
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NDT Issues With the Composites
Industry
y Still hard to distinguish between:
y Broken/fractured structural fibers
y Resin matrix cracking
y Problems at interfaces ‐‐‐ e.g. adhesive joints
y Honeycomb core bond interfaces
y “Kissing” unbonds (stick together !)
y Cryogenic tank problems
y Aircraft composite tail & rudder issues
y Core material defects, cracks, unbonds
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55
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American Airlines Flight 587 rudder
Clean face-core disbond
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60
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Where ‘s
the rudder?
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Fiber Placement
y Preimpregnated carbon fiber band is laid onto a
mandrel or shaped surface using complex, automated
equipment:
y Carbon fiber (IM7) tow about 0.125 ‐inch wide
y `Tow’ impregnated with 977‐2 epoxy resin
y Fiber angle, orientation controlled precisely
y `Tow’ is laid onto surface with light normal pressure
against the surface
y Subsequent layers built upon first layer
y Resulting structure cured after completion
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Fiber Placement Operation
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Honeycomb Core
y Lightweight, expanded core looks like cardboard cross‐
section
y Core cells are essentially hexagonal in shape ‐‐ with air in
the center
y Cell wall material is Kevlar (Aramid)/resin
y Kevlar used because its density is 1.4 g/cm3
y Core must be bonded to fiber‐placed carbon/epoxy `skins’
to provide strength
69
Film Adhesive
y Film adhesive is a form of epoxy `glue’
y Adhesive form is uncured but thick paste form essentially
y One side of film adhesive has lightweight cloth `scrim’ to
keep adhesive from running
y Film adhesive very thin (0.05‐0.10 inch)
y Film adhesive bonds carbon skins to honeycomb core
structure
70
Microcracking
y Microcracking are extremely `small’ cracks within carbon
fiber/epoxy laminate:
y Result from thermal `mismatch’
y Carbon fiber ‐‐ low expansion
y Epoxy resin ‐‐ high expansion
y Result from high residual `loads’ or stresses
y Result from fatigue or cycling loads
y Result from cooling to extremely low temperatures (LH2,
LOX, LN2, etc)
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Permeability
y Laminate porosity, cracking, voids, gaps, and
microcracking areas allow gases and/or liquids to migrate
through the thickness
y High permeability ‐‐ fast diffusion (sieve)
y Low permeability ‐‐ slow diffusion (seal)
y Smaller molecules (hydrogen) migrate more easily
through smaller cracks than larger molecules (oxygen,
helium, nitrogen, air)
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X‐33 Liquid
Hydrogen Tank
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Cryogenic Microcracking
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Lobe #1/Tanks #1 NDI Map of
Sandwich Construction Areas
y Ultrasonic testing
used for NDI of
Lobe/Tank surface
structure
y `Good’ and `bad’
areas mapped out
on structure
76
Visual Damage Observed on
Lobe #1 (After Autoclave Run 4A)
Inner Facesheet Damage
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Film Adhesive Filleting (Inner
Skin ‐‐ Normal Filleting)
y Well‐defined adhesive
fillets form on
honeycomb cell walls
y Adhesive thickness
more uniform
y No bubbles or voids
y Develops better bond
strength allowables
78
Film Adhesive Filleting (Outer
Skin ‐‐ Poor Filleting)
y Lack of filleting down
honeycomb cell side
walls
y Lack of uniform film
adhesive thickness
y Separation of film
from composite
laminate (voids)
y Thin film areas
79
Summary
y Some simple methods work very well
y NDT issues still remain:
y Kissing unbonds are difficult to find/assess
y Fiber breakage and resin cracking hard to distinguish with
methods available
y Structural performance requires “destructive” tests in
conjunction with NDT and analysis
y Honeycomb core interfaces are difficult
y Visual will not usually detect internal defects
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BTG Composites Inc.

Titan IV A-20 Delta III

Decades of technical development provide a strong

The first method of

100µm FD: 50µm FD:

Clean face-core disbond

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