A Review of Nondestructive Testing Methods for Aerospace Composite Materials

Authors

  • Md. Shaishab Ahmed Shetu Department of Aeronautical and Aviation Science and Engineering, College of Aviation Technology, National University of Bangladesh, Gazipur, Dhaka, Bangladesh 1230

DOI:

https://doi.org/10.57159/gadl.jcmm.3.1.240117

Keywords:

Non-Destructive Testing, Composite material, Ultrasound, Shearography, Inspection

Abstract

Composite structures and materials have seen significant advancements in cost-effectiveness, product efficiency, and specific properties, leading to their extensive use in the aerospace industry. Reliable nondestructive testing (NDT) of composites is crucial for reducing maintenance costs and addressing safety concerns. This review provides a comprehensive analysis of various NDT methods, including Ultrasonic Testing, Acoustic Emission, Eddy Current Testing, Shearographic Testing, Infra-Red Thermography, and X-Ray Radiography. Each method’s principles, instruments, and applications for defect detection and damage evaluation in composite materials are thoroughly examined. The paper highlights the strengths and limitations of these NDT techniques, emphasizing their roles in ensuring the structural integrity of aerospace composites. Ultrasonic Testing and Infra-Red Thermography are identified as flexible and cost-effective solutions, widely applied in both academic research and industrial sectors. Despite the challenges in providing a complete diagnostic of structural integrity, each NDT method offers unique advantages. Future research in NDT for composites will focus on integrating advanced data processing techniques, such as machine learning and deep learning, and developing smart inspection systems with high precision and rapid data processing capabilities.

References

Here is the entire list in the specified plain text format:

C. Soutis, “Fibre reinforced composites in aircraft construction,” Progress in Aerospace Sciences, vol. 41, no. 2, pp. 143–151, 2005.

A. Katunin, K. Dragan, and M. Dziendzikowski, “Damage identification in aircraft composite structures: A case study using various nondestructive testing techniques,” Composite Structures, vol. 127, pp. 1–9, 2015.

H. Towsyfyan, A. Biguri, R. Boardman, and T. Blumensath, “Successes and challenges in nondestructive testing of aircraft composite structures,” Chinese Journal of Aeronautics, vol. 33, no. 3, pp. 771–791, 2020.

U. Ewert et al., “Mobile computed tomography for inspection of large stationary components in nuclear and aerospace industries,” Materials Transactions, vol. 53, no. 2, pp. 308–310, 2012.

O. Bullinger, U. Schnars, D. Schulting, B. Redmer, M. Tschaikner, and U. Ewert, “Laminographic inspection of large carbon fiber composite aircraft-structures at Airbus,” 19th World Conference on Nondestructive Testing, pp. 1–10, 2016.

K. E. Cramer, “Current and future needs and research for composite materials NDE,” vol. 1059603, no. March 2018, pp. 500, 2018.

X. Li, “Eddy current techniques for nondestructive testing of carbon fiber reinforced plastic (CFRP),” pp. 725–728, 2013.

H. Kim, “Impact damage formation on composite aircraft structures,” Federal Aviation Administration JAMS 2012 Technical Review Meeting, pp. 1–58, 2012.

R. A. Smith, “Composite defects and their detection,” vol. III.

X. E. Gros, “An eddy current approach to the detection of damage caused by low-energy impacts on carbon fiber reinforced materials,” Materials & Design, vol. 16, no. 3, pp. 167–173, 1995.

C. Soutis, “Carbon fiber reinforced plastics in aircraft construction,” Materials Science and Engineering: A, vol. 412, no. 1–2, pp. 171–176, 2005.

A. Katunin, K. Dragan, and M. Dziendzikowski, “Damage identification in aircraft composite structures: A case study using various nondestructive testing techniques,” Composite Structures, vol. 127, pp. 1–9, 2015.

P. Gharghabi, J. Lee, M. S. Mazzola, and T. E. Lacy, “Development of an experimental setup to analyze carbon/epoxy composite subjected to current impulses,” Proceedings of the American Society for Composites - 31st Technical Conference, ASC 2016, 2016.

P. K. Mallick, “Fiber-reinforced composites: Materials, manufacturing, and design,” Boca Raton: CRC Press, 2007.

P. Duchene, S. Chaki, A. Ayadi, and P. Krawczak, “A review of nondestructive techniques used for mechanical damage assessment in polymer composites,” Journal of Materials Science, vol. 53, no. 11, pp. 7915–7938, 2018.

H. Towsyfyan, A. Biguri, R. Boardman, and T. Blumensath, “Successes and challenges in nondestructive testing of aircraft composite structures,” Chinese Journal of Aeronautics, vol. 33, no. 3, pp. 771–791, 2020.

S. Heimbs, S. Heller, P. Middendorf, F. Hähnel, and J. Weiße, “Low velocity impact on CFRP plates with compressive preload: Test and modelling,” International Journal of Impact Engineering, vol. 36, no. 10–11, pp. 1182–1193, 2009.

S. Heimbs, T. Bergmann, D. Schueler, and N. Toso-Pentecôte, “High velocity impact on preloaded composite plates,” Composite Structures, vol. 111, no. 1, pp. 158–168, 2014.

A. Tiwary, “Ultrasonic testing (UT): Definition, principle, working, types & methods,” 2019. [Online]. Available: https://www.engineersrail.com/ultrasonic-testing/

S. R. Doctor, T. E. Hall, and L. D. Reid, “SAFT - the evolution of a signal processing technology for ultrasonic testing,” NDT International, vol. 19, no. 3, pp. 163–167, 1986.

A. Benammar, R. Drai, and A. Guessoum, “Detection of delamination defects in CFRP materials using ultrasonic signal processing,” Ultrasonics, vol. 48, no. 8, pp. 731–738, 2008.

S. S. Technologies, “Health monitoring of aerospace structures,” 2003.

F. Honarvar, H. Sheikhzadeh, M. Moles, and A. N. Sinclair, “Improving the time-resolution and signal-to-noise ratio of ultrasonic NDE signals,” Ultrasonics, vol. 41, no. 9, pp. 755–763, 2004.

E. Jasiūnienė, L. Mažeika, V. Samaitis, V. Cicėnas, and D. Mattsson, “Ultrasonic nondestructive testing of complex titanium/carbon fiber composite joints,” Ultrasonics, vol. 95, pp. 13–21, 2019.

P. Cawley and R. Adams, “Defect types and nondestructive testing techniques for composites and bonded joints. Materials science and technology, 1989. 5(5): p. 413-425.,” Materials Science and Technology, vol. 5, no. May, pp. 413–425, 1989.

R. Ramzi, M. F. Mahmod, and E. A. Bakar, “Immersion ultrasonic inspection system for small scaled composite specimen,” ARPN Journal of Engineering and Applied Sciences, vol. 10, no. 22, pp. 17146–17150, 2015.

K. K. Borum, “Evaluation of the quality of thick fiber composites using immersion and air-coupled ultrasonic techniques,” European conference on nondestructive testing., German Society for Nondestructive Testing, 2006.

L. Gao, F. Zai, S. Su, H. Wang, P. Chen, and L. Liu, “Study and application of acoustic emission testing in fault diagnosis of low-speed heavy-duty gears,” Sensors, vol. 11, no. 1, pp. 599–611, 2011.

S. Gholizadeh, Z. Lemana, and B. T. H. T. Baharudin, “A review of the application of acoustic emission technique in engineering,” Structural Engineering and Mechanics, vol. 54, no. 6, pp. 1075–1095, 2015.

J. Arumugam, C. S. Kumar, C. Santulli, F. Sarasini, and A. J. Stanley, “A global method for the identification of failure modes in fiberglass using acoustic emission,” Journal of Testing and Evaluation, vol. 39, no. 5, pp. 1–13, 2011.

Y. H. Yu, J. H. Choi, J. H. Kweon, and D. H. Kim, “A study on the failure detection of composite materials using an acoustic emission,” Composite Structures, vol. 75, no. 1–4, pp. 163–169, 2006.

B. Wang, S. Zhong, T. L. Lee, K. S. Fancey, and J. Mi, “Nondestructive testing and evaluation of composite materials/structures: A state-of-the-art review,” Advances in Mechanical Engineering, vol. 12, no. 4, pp. 1–28, 2020.

A. Hase, H. Mishina, and M. Wada, “Correlation between features of acoustic emission signals and mechanical wear mechanisms,” Wear, vol. 292–293, pp. 144–150, 2012.

J. Y. Liu, P. F. Chu, J. K. Liu, and Y. L. Zheng, “A study on the failure mechanisms of carbon fiber/epoxy composite laminates using acoustic emission,” Materials & Design, 2012.

C. R. Ramirez-Jimenez, N. Papadakis, N. Reynolds, T. H. Gan, P. Purnell, and M. Pharaoh, “Identification of failure modes in glass/polypropylene composites by means of the primary frequency content of the acoustic emission event,” Composites Science and Technology, vol. 64, no. 12, pp. 1819–1827, 2004.

H. Towsyfyan, “Behaviour of mechanical seals for online condition monitoring,” Ph.D. Thesis, 2017, p. 237.

H. Nechad, A. Helmstetter, R. El Guerjouma, and D.

Sornette, “Creep ruptures in heterogeneous materials,” Physical Review Letters, vol. 94, no. 4, pp. 1–4, 2005.

H. Y. Chou, A. P. Mouritz, M. K. Bannister, and A. R. Bunsell, “Acoustic emission analysis of composite pressure vessels under constant and cyclic pressure,” Composites Part A: Applied Science and Manufacturing, vol. 70, pp. 111–120, 2015.

S. Huguet, N. Godin, R. Gaertner, L. Salmon, and D. Villard, “Use of acoustic emission to identify damage modes in glass fiber reinforced polyester,” Composites Science and Technology, vol. 62, no. 10–11, pp. 1433–1444, 2002.

N. Godin, S. Huguet, R. Gaertner, and L. Salmon, “Clustering of acoustic emission signals collected during tensile tests on unidirectional glass/polyester composite using supervised and unsupervised classifiers,” NDT & E International, vol. 37, no. 4, pp. 253–264, 2004.

E. Z. Kordatos, K. G. Dassios, D. G. Aggelis, and T. E. Matikas, “Rapid evaluation of the fatigue limit in composites using infrared lock-in thermography and acoustic emission,” Mechanics Research Communications, vol. 54, pp. 14–20, 2013.

B. Wang, S. Zhong, T. L. Lee, K. S. Fancey, and J. Mi, “Nondestructive testing and evaluation of composite materials/structures: A state-of-the-art review,” Advances in Mechanical Engineering, vol. 12, no. 4, pp. 1–28, 2020.

P. Vaara and J. Leinonen, “Technology survey on NDT of carbon-fiber composites,” 2012.

X. E. Gros, “Characterization of low energy impact damages in composites.”

J. C. Moulder, E. Uzal, and J. H. Rose, “Thickness and conductivity of metallic layers from eddy current measurements,” Review of Scientific Instruments, vol. 63, no. 6, pp. 3455–3465, 1992.

P. Chandra and R. Bhagi, “Basics eddy current testing: Basics,” May, 2014.

G. Mook, R. Lange, and O. Koeser, “Nondestructive characterisation of carbon-fibre-reinforced plastics by means of eddy-currents,” Composites Science and Technology, vol. 61, no. 6, pp. 865–873, 2001.

J. Cheng, J. Qiu, H. Ji, E. Wang, T. Takagi, and T. Uchimoto, “Application of low frequency ECT method in noncontact detection and visualization of CFRP material,” Composites Part B: Engineering, vol. 110, pp. 141–152, 2017.

G. Y. Tian and A. Sophian, “Reduction of lift-off effects for pulsed eddy current NDT,” NDT & E International, vol. 38, no. 4, pp. 319–324, 2005.

Y. Y. Hung and H. P. Ho, “Shearography: An optical measurement technique and applications,” Materials Science and Engineering: R: Reports, vol. 49, no. 3, pp. 61–87, 2005.

Q. Zhao, X. Dan, F. Sun, Y. Wang, S. Wu, and L. Yang, “Digital shearography for NDT: Phase measurement technique and recent developments,” Applied Sciences (Switzerland), vol. 8, no. 12, 2018.

H. J. T. Pedrini, G. and Y. L. Zou, “Quantitative evaluation of digital shearing interferogram using the spatial carrier method,” Pure and Applied Optics: Journal of the European Optical Society.

M. K. Kalms, W. Osten, and W. P. O. Jueptner, “Advanced shearographic system for nondestructive testing of industrial and artwork components,” Lasers in Material Processing and Manufacturing, vol. 4915, September 2002, p. 34, 2002.

Y. Y. Hung, “Applications of digital shearography for testing of composite structures,” Composites Part B: Engineering, vol. 30, no. 7, pp. 765–773, 1999.

J. W. Newman, “Aerospace NDT with advanced laser shearography,” 17th World Conference on Nondestructive Testing, pp. 25–28, 2008.

Y. Y. Hung, W. D. Luo, L. Lin, and H. M. Shang, “Evaluating the soundness of bonding using shearography,” Composite Structures, vol. 50, no. 4, pp. 353–362, 2000.

J. R. Lee, J. Molimard, A. Vautrin, and Y. Surrel, “Application of grating shearography and speckle shearography to mechanical analysis of composite material,” Composites Part A: Applied Science and Manufacturing, vol. 35, no. 7–8, pp. 965–976, 2004.

F. Taillade, M. Quiertant, K. Benzarti, and C. Aubagnac, “Shearography and pulsed stimulated infrared thermography applied to a nondestructive evaluation of FRP strengthening systems bonded on concrete structures,” Construction and Building Materials, vol. 25, no. 2, pp. 568–574, 2011.

*Dr. Ip recently joined the Mechanical Engineering Department of Hong Kong University., pp. 1–46.

G. De Angelis, M. Meo, D. P. Almond, S. G. Pickering, and S. L. Angioni, “A new technique to detect defect size and depth in composite structures using digital shearography and unconstrained optimization,” NDT & E International, vol. 45, no. 1, pp. 91–96, 2012.

W. J. Murri et al., “Defects in thick composites and some methods to locate them advanced methods group, physics division introduction nondestructive evaluation (NDE) of thick composites is a difficult If ultrasonic techniques are used, such factors as attenuation (prefe),” pp. 1583–1584, 1991.

Y. Y. Hung, L. X. Yang, and Y. H. Huang, “Nondestructive evaluation (NDE) of composites: Digital shearography,” no. 1. 2013.

S. Gholizadeh, “A review of nondestructive testing methods of composite materials,” Procedia Structural Integrity, vol. 1, pp. 50–57, 2016.

J. Lee, F. Wu, W. Zhao, M. Ghaffari, L. Liao, and D. Siegel, “Prognostics and health management design for rotary machinery systems - Reviews, methodology and applications,” Mechanical Systems and Signal Processing, vol. 42, no. 1–2, pp. 314–334, 2014.

H. O. Nyongesa, A. W. Otieno, and P. L. Rosin, “Neural fuzzy analysis of delaminated composites from shearography imaging,” Composite Structures, vol. 54, no. 2–3, pp. 313–318, 2001.

C. Meola, “Infrared thermography: Recent advances and future trends,” Sharjah, UAE: Bentham eBooks, 2012.

Y. K. Zhu, G. Y. Tian, R. S. Lu, and H. Zhang, “A review of optical NDT technologies,” Sensors, vol. 11, no. 8, pp. 7773–7798, 2011.

S. Pickering and D. Almond, “Matched excitation energy comparison of the pulse and lock-in thermography NDE techniques,” NDT & E International, vol. 41, no. 7, pp. 501–509, 2008.

R. Mulaveesala, G. Dua, and V. Arora, “Applications of infrared thermography for nondestructive characterization of concrete structures,” Advances in Structural Health Monitoring, pp. 1–16, 2019.

K. E. Cramer, “Current and future needs and research for composite materials NDE,” vol. 1059603, no. March 2018, pp. 500, 2018.

ASTM, “Practice for infrared flash thermography of composite panels and repair patches used in aerospace applications. Report No: E2582-07,” 2007.

F. Ciampa, P. Mahmoodi, F. Pinto, and M. Meo, “Recent advances in active infrared thermography for nondestructive testing of aerospace components,” Sensors (Switzerland), vol. 18, no. 2, 2018.

F. Khodayar, F. Lopez, C. Ibarra-Castanedo, and X. Maldague, “Optimization of the inspection of large composite materials using robotized line scan thermography,” Journal of Nondestructive Evaluation, vol. 36, no. 2, 2017.

D. Bates, G.

Smith, D. Lu, and J. Hewitt, “Rapid thermal nondestructive testing of aircraft components,” Composites Part B: Engineering, vol. 31, no. 3, pp. 175–185, 2000.

F. Khodayar, F. Lopez, C. Ibarra-Castanedo, and X. Maldague, “Parameter optimization of robotized line scan thermography for CFRP composite inspection,” Journal of Nondestructive Evaluation, vol. 37, no. 1, 2018.

B. Wiecek, “Review on thermal image processing for passive and active thermography,” Annual International Conference of the IEEE Engineering in Medicine and Biology - Proceedings, vol. 7 VOLS, pp. 686–689, 2005.

S. Doshvarpassand, C. Wu, and X. Wang, “An overview of corrosion defect characterization using active infrared thermography,” Infrared Physics & Technology, vol. 96, no. November 2018, pp. 366–389, 2019.

P. Theodorakeas, E. Cheilakou, E. Ftikou, and M. Koui, “Passive and active infrared thermography: An overview of applications for the inspection of mosaic structures,” Journal of Physics: Conference Series, vol. 655, no. 1, 2015.

X. Maldague, “Theory and practice of infrared technology for nondestructive testing,” Hoboken: John Wiley & Sons, 2001.

T. Zweschper, G. Riegert, A. Dillenz, and G. Busse, “Ultrasound excited thermography - advances due to frequency modulated elastic waves,” Quantitative Infrared Thermography Journal, vol. 2, no. 1, pp. 65–76, 2005.

B. Yang, Y. Huang, and L. Cheng, “Defect detection and evaluation of ultrasonic infrared thermography for aerospace CFRP composites,” Infrared Physics & Technology, vol. 60, pp. 166–173, 2013.

J. Wilson, G. Y. Tian, I. Z. Abidin, S. Yang, and D. Almond, “Modelling and evaluation of eddy current stimulated thermography,” Nondestructive Testing and Evaluation, vol. 25, no. 3, pp. 205–218, 2010.

T. J. Ahmed, G. F. Nino, H. E. N. Bersee, and A. Beukers, “Heat emitting layers for enhancing NDE of composite structures,” Composites Part A: Applied Science and Manufacturing, vol. 39, no. 6, pp. 1025–1036, 2008.

C. Meola et al., “Impact damaging of composites through online monitoring and nondestructive evaluation with infrared thermography,” NDT & E International, vol. 85, pp. 34–42, 2017.

M. Ishikawa and M. Koyama, “Influence of composite ply layup on active thermographic nondestructive inspection of carbon fiber-reinforced plastic laminates,” Journal of Nondestructive Evaluation, vol. 37, no. 2, 2018.

H. Towsyfyan, A. Biguri, R. Boardman, and T. Blumensath, “Successes and challenges in nondestructive testing of aircraft composite structures,” Chinese Journal of Aeronautics, vol. 33, no. 3, pp. 771–791, 2020.

C. Maierhofer, P. Myrach, M. Reischel, H. Steinfurth, M. Röllig, and M. Kunert, “Characterizing damage in CFRP structures using flash thermography in reflection and transmission configurations,” Composites Part B: Engineering, vol. 57, pp. 35–46, 2014.

D. P. Almond and W. Peng, “Thermal imaging of composites,” Journal of Microscopy, vol. 201, no. 2, pp. 163–170, 2001.

C. D. Lockard, “Anomaly detection in radiographic images of composite materials via crosshatch regression.”

H. Rolland, N. Saintier, P. Wilson, J. Merzeau, and G. Robert, “In situ X-ray tomography investigation on damage mechanisms in short glass fibre reinforced thermoplastics: Effects of fibre orientation and relative humidity,” Composites Part B: Engineering, vol. 109, pp. 170–186, 2017.

S. Gholizadeh, “A review of nondestructive testing methods of composite materials,” Procedia Structural Integrity, vol. 1, pp. 50–57, 2016.

S. Saber and G. I. Selim, “Higher-order statistics for automatic weld defect detection,” Journal of Software Engineering and Applications, vol. 6, no. 5, pp. 251–258, 2013.

F. J. Guild, N. Vrellos, B. W. Drinkwater, N. Balhi, S. L. Ogin, and P. A. Smith, “Intra-laminar cracking in CFRP laminates: Observations and modelling,” Journal of Materials Science, vol. 41, no. 20, pp. 6599–6609, 2006.

A. Ataş and C. Soutis, “Subcritical damage mechanisms of bolted joints in CFRP composite laminates,” Composites Part B: Engineering, vol. 54, no. 1, pp. 20–27, 2013.

Downloads

Published

29-02-2024

How to Cite

Shetu, M. S. A. (2024). A Review of Nondestructive Testing Methods for Aerospace Composite Materials. Journal of Computers, Mechanical and Management, 3(1), 30–41. https://doi.org/10.57159/gadl.jcmm.3.1.240117

Issue

Section

Invited Article

Categories