non -contact ultrasound composites analysis ultrasound: composites analysis application note...
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www.ultrangroup.com
Non-Contact Ultrasound
COMPOSITES ANALYSIS
Application Note AN-305-1
SecondWave™ M510 Ultrasonic Analysis System
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
2
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
SecondWave™ M510 shown with single and multi-channel transducers on different materials
Introduction
Contact or water immersion ultrasound does provide
significant information about materials quality and
properties. But, it cannot be applied to the early stages
of materials formation - when they are tacky or fragile.
It is also not reliable for materials that are porous, liquid
sensitive, or when any type of contact with a material is
cumbersome. Non-Contact Ultrasound (NCU) is the
most desirable choice for such applications.
Ultran has been working to facilitate NCU since 1978. In
1997, Ultran created internationally patented
piezoelectric transducers characterized by phenomenal
efficiency in air and other gases with frequencies from
50 kHz to 5.0 MHz. Complementing the NCU
transducers are Ultran’s equally novel ultrasonic imaging
systems and analyses software. The SecondWave™
M510 is a focused non-contact ultrasonic analysis
system that is customer-friendly and understands the
significance of materials testing and analysis, including
the speeds required to accomplish a task.
The M510 supports through transmission, same-side
and pulse-echo techniques. M510 single and multi-
channel systems have been fully configured and
installed for on-line (production line) and off-line (bench
top)composites all the way from uncured to cured
stages and finished products.
M510 Capabilities
Inhomogeneous resin distribution detection
High resolution delamination and defect detection in
sandwich structures – CFRP, GFRP, and metal skins
bonded to each other or to NOMEX and foam cores
Porosity estimation
Fiber content, misalignment, and orientation
Through transmission and same side testing
SecondWave™ M510 Components
NCU Transducers
Ultran’s transducers boast the highest efficiency devices
among non-contact transducers – approaching those of
conventional contact transducers. Frequency Range: 50
kHz - 5.0 MHz. Active dimensions: 1.0 mm - 500mm.
with planar, point, parabolic, and compound beam
geometry. Robust lightweight construction.
Scanning: Vertical or horizontal acoustic bench, single or
multi-transducer multi-axis scanning frames.
System Instrumentation
4U industrial grade unit incorporating Intel Core2 Quad
processors, 2 GB RAM, RAID5 Serial ATA hard drives and
redundant power supplies. Integrated are:
Pulser: PCI-based 375V RF toneburst pulser with 50 kHz
to 5 MHz range, adjustable bursts, voltage and PRF.
Receiver: Internal 1-8 channel low-noise amplifier with
80 dB gain and 10 MHz bandwidth, multi-value low and
high pass filters.
DAQ: 14 bit Analog to Digital Converter with 50 MHz
sample rate and on-board 256 MB storage. Multi-axis
encoder inputs for motion synchronized acquisition.
Software
SecondWave™ Studio: Windows XP-based A-Scan and
C-Scan software with user-friendly GUI. Displays rolling
single and multi-channel C-Scans. Capture and storage
of full-wave data for scans. Project Manager with
multipleaccess levels. SQL Database integration.
SecondWave™ Research Studio: C-Scan and A-Scan
post-processing software. Generates cross-sectional
material profiles. Parametric correlation to determine
material density, porosity and fiber orientation. Image
processing functions to find and highlight defects.
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
3
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Non-contact ultrasound techniques
Direct transmission
Same side transmitter-receiver – pitch-catch
T R
Longitudinal/Shear
Waves
Surface WavesAIR
Single transducer – pulse-echo
AIR
Quantitative detectability example
Defect, crack, delamination detection
Velocity, time-of-flight, thickness measurements
Oblique incidence & refraction for shear wave and
anisotropy measurements
Transmittance measurement
Defect, delamination,
corrosion detection
Location of discontinuities
Surface profiling
Surface acoustic analysis
Reflectance measurements
Depth measurement
Object identification
Air + Test
Material
Transmission
Surface
Reflections
Thickness
Reflections
Detection of side drilled holes (varying
from 0.5 to 6.3 mm) in 10 mm PMMA
with direct NCU transmission – 1.0 MHz
Ultrasonic reflection image
AIR
T
R
AIR
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
4
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Observations and case studies by direct transmission and same side NCU imaging (All images generated without signal post-processing, and in most cases no signal averaging was used)
Prepregs and consolidated laminates – defect detection and porosity measurement – figures 1 to 4
Fig. 3. Porosity in CFRP
composite – left, zero
porosity, middle and right,
gross porosity, <1 to >4%.
1.0 MHz and 500 kHz.
Fig. 4: 19 mm CFRP-GFRP cylindrical*
composite section showing bonded and
severely disbonded regions. 140 kHz.
Severity of bond quality can be
estimated by quantitative analysis
shown in cross-sectional profiles.
*Shape effects have been eliminated
and edge effects substantially reduced
by special NCU techniques.
Fig. 1. Top: 1.5 mm
CFRP prepreg with
trapped protective
papers – 500 kHz
Bottom: 4.0 mm
CFRP prepreg with
trapped protective
film – 200 kHz.
Fig. 2. Uncured (left) and
cured (right) CFRP composite.
Lighter regions in cured
material indicates porosity,
also confirmed in uncured
state by thin section
microscopy - 500 kHz.
By permission, HEXCEL
Composites, UK.
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
5
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Large GFRP panels – defects, delaminations, and density variations – Fig. 5
Honeycomb sandwich structures – defects and delaminations – figures 6 to 10
Fig. 7. 19 mm Al honeycomb with Fig. 8. 50 mm NOMEX honeycomb with 2 mm CFRP skins - 200 kHz.
0.25 mm Al skins - 500 kHz.
Fig. 5. Very large
panels of 4 mm
GFRP composite
with overt defects
- 500 kHz.
Fig. 6. 13 mm NOMEX with 1 mm CFRP skins. 1.0 MHz
Fig. 10. Very high
resolution in GFRP
skins NOMEX
composite.
1.0 MHz
Fig. 9. 10 mm Al-Al
honeycomb
helicopter
component - 140 kHz
Fig. 6a. CFRP skins; thick NOMEX honeycomb
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
6
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
High temperature graphitized woven carbon fiber composites for texture analysis and defect
detection – figures 11 and 12
SMC materials -- Homogeneity and fiber orientation detection – Fig. 13
Carbon-Carbon disc brakes – density variations and defects – figures 14 and 15
Fig. 15. Jumbo jet brake section. 200 kHz.
Fig. 13. Unwanted glass
fiber alignment in an
otherwise
homogeneous sheet
molded composite with
chopped fibers.
500 kHz.
Fig. 11. 3 mm C-C
composite with
sever texture
variation and
porosity- 500 kHz.
Fig. 12. Another
sample analogous
to Fig. 11, with
overt defects.
Fig. 14. High
performance
automobile brake. 200
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
7
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Multiple sheets of bonded aluminum – figure 16
Very high resolution NCU of composites – figure 18
Fig. 18. Two samples
of Carbon-Carbon
composites,
indicating broken
fibers and porous
regions- 1.0 MHz.
Fig 17: Flap section of used F-16
honeycomb
Non-Contact Ultrasound: Composites Analysis
Application Note AN-305-1
8
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Conclusions
Ultran’s SecondWave™ M510 ultrasonic imaging and
analysis system is characterized by a wide range of
frequencies from 50 kHz to 5.0 MHz. This makes it
possible to apply non-contact ultrasound (NCU) for
composites evaluation all the way from early stages
of their formation to finished products. Typical
applications include defect and delamination
detection, porosity and texture analysis, properties,
etc. The M510 is a powerful tool for materials process
analysis and QC, directly saving you cost, energy, and
materials, besides assuring the quality and reliability
of your materials.
What Ultran provides
We supply fully configured NCU systems suitable for
customers’ needs. These include specifically
designed transducer libraries so that our customers
can start characterizing all their materials from Day 1.
Ultran also supplies custom NCU systems geared for
production (online) configured to customers’
applications and environment of testing.
Under agreements, Ultran will transfer science and
technology -targeted to customer needs. We offer
hands-on training to all our customers.
We maintain a fully-stocked ultrasound materials
analytical laboratory and we are fully equipped to
provide feasibility, in-depth analysis, and R&D for our
customers.
Sales representatives
HEAD OFFICE
The Ultran Group
3100 Research Drive
State College, PA 16801 USA
Tel: +1.814.466.6200
Fax: +1.814.466.6847
Email: info@ultrangroup.com
ITALY
Pierluigi Carni
Via B. Angelico, 1
24047 Treviglio – BG, Italy
Tel: +39 340 9125410
Email: plcarni@atenatec.it
UK
Sonatest NDTS
Jenny Hough
Units 1-3 Prospect House, Colliery Close,
Ireland Business Park,
Staveley, Chesterfield, S41 8NG, UK
Tel: +44 (0) 1246 474269
Fax: +44 (0) 1246 474089
Email: jenny.hough@sonatest.com
JAPAN
Ken Automation
Tatsuya Yaoita
Hiranuma 1-11-12
Yokohama KMH Bldg., Nishi-Ku
Yokohama - 220-0023
Tel: +81.45.290.0432
Fax: +81.45.321.6590
Email: yaoita@kenautomation.com
CHINA
Matrix U/E Technologies Inc.
Jiang Yunxi
Chaoyang District, Beijing Wangjing Litse emerging
industries in Park District No. 106 Building 402B
Tel:+86-10-64391208-819
Mobile: 0086-13910978697
E-Mail: jiangyunxi@matrixndt.com
INDIA
Simon Amallraja
President - SMD
PET Aviation Systems P Ltd.
Mobile: +91 98663-43309, +91 98480-43309
Tel: +91-40-2370-2840, Fax: +91-40-2370-2837
Email: amallraja@petaviation.com
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