ULTRASONIC INSPECTION OF COMPOSITES:

CHALLENGES AND SOLUTIONS FOR

IMPROVED PRODUCT QUALITY

S. Mahaut, S. Legoupil, F. Grassin, CEA-LIST, Saclay, France

H. Walaszek, CETIM, Senlis, France
 Outlines

Context

Part I (CEA) : Simulation as a tool for ultrasonic NDT of composites

• Simulation tools for ultrasonic inspection
• Examples of applications

Part II (CEA/CETIM) : The « CAPME’UP » initative. Targeting NDT solutions for SMEs
• Motivation of the CAPME’UP project
• Development of

Part III (CETIM) : Innovative NDT methods for composites

• Phased array ultrasonics
• Thermography
• Computed X-ray tomography

Conclusion and Perspectives

Aerodatings, October 1st, 2013. CEA/CETIM

 CONTEXT : Composites
Complex structures and geometries

Thickness variations (Highly) curved parts

Stiffened panel

Specific defects to be assessed in composite structures

Porosity (black) delaminations

Ply waviness

+ other potential flaws : microcracks, inserts…

Aerodatings, October 1st, 2013. CEA/CETIM

PART I :

SIMULATION OF ULTRASONIC
INSPECTION
 Ultrasonic models in
Simulation of radiated field : Simulation of echographic response :
Surface integral over the probe (« pencils » method) Reciprocity + scattering coefficients)

t = 44 µs

• Prediction of actual inspection

performances
• Probe design (eg, Phased Arrays) • Parametric studies
• Zone coverage • Analysis of complex inspection
• Analysis results

Adaptation to composites (anisotropic/heterogeneous + complex parts) ?

Aerodatings, October 1st, 2013. CEA/CETIM
 COMPOSITE AND UT SCALES
Heterogeneous Anisotropic
Slowness curves,
One ply
orthotropic
symmetry

16 plies ~
Typical sound speeds for
1 λ (10 MHz) Quasi-longitudinal waves
• ~ 3000 m/s
perpendicular to fibers
Different scales :
plane
• carbon fibers : φ ~ 7 µm
• ~ 9000 m/s along fiber
• Plies : from 125 to 250 µm
direction

NDT scale : λ ~ 6 mm to 0.2 mm (@ f=1 to 15 MHz) The meso-scale has to be considered

Depending on the complexity of the configuration (material + geometry) and the frequency of the
UT probe, different strategies may be carried out :

• Semi-Analytical (Integral methods) on homogenized materials

• Numerical (or mixed Analytical/Numerical) for complex structures and/or flaws

Aerodatings, October 1st, 2013. CEA/CETIM

 HOMOGENIZATION APPROACHES
PhD S. Lonné with

0°
Inputs: matrix + carbon fibers description (material properties)
Outputs: equivalent anisotropic material (UT NDT properties : elastic constants + attenuation)

obliquely incident
plane wave

A A
00°
c V(e1 ) d1
Cscan PhD S. Deydier
e
90°
V(e2 ) d2 D with
stacking d
sequence d
to be
45° V(e3 ) d3
e
homogenized V(e4 )
- 45°
d4
periodically repeated B B
stacking sequence

Inputs: Stacking sequence and plies description (material properties)

Outputs: equivalent anisotropic material (UT NDT properties : elastic constants + attenuation)

Aerodatings, October 1st, 2013. CEA/CETIM

 HOMOGENIZATION APPROACHES
Application and experimental validation
Multi-ply composite
Measure of the UT
field transmitted [1] [2] [3]
through the
composite
water
5.4 mm 8° 10.8 mm

Simulation of the composite part

(decomposed into homogenized 7°
domains) (ρ*,Cij*) 5° (ρ*,Cij*)
(ρ*,Cij*) 3°
1°

0 dB
(refce)
- 6 dB
Simulation
- 10 dB
Measure

-2 0
0
Good prediction of deviation/attenuation of the UT field through the composite parts
Aerodatings, October 1st, 2013. CEA/CETIM
 HOMOGENEOUS APPROACHES
DYNAMIC PENCIL METHOD FOR PROPAGATION WITHIN A ANISOTROPIC CURVED PART
• Adaptation of the Ultrasonic models to take account of curved composites
(Application : stiffener, ribs, stringers …)
- CIVA UT model - Numerical (ACEL)
Depth 5 mm

Depth 15 mm

Depth 30 mm

UT beam inside
the curved part

Aerodatings, October 1st, 2013. CEA/CETIM

 HYBRID MODELING APPROACHES
PRINCIPLE OF THE HYBRID METHOD : CIVA/ACEL-NDT (FDTD CODE, N. DOMINGUEZ)

Development and integration of a coupling code in CIVA : CIVA/ACEL-NDT

1. Emission: semi-analytical
→ Input field at the FDTD box upper boundary
Semi-analytical path
2. FDTD propagation in the box
→ Output field at the FDTD box upper boundary
+ Field in FDTD box (propag. movie) Exchange surface

3. Reception: Auld reciprocity (semi-analytical)

→ Pressure field on receiver
FDTD box

Aerodatings, October 1st, 2013. CEA/CETIM

 HYBRID MODELING APPROACHES
APPLICATION OF THE HYBRID CIVA/ACEL CODE
Propagation through a « safe » part Propagation through a part with ply waviness

Aerodatings, October 1st, 2013. CEA/CETIM

 HYBRID MODELING APPROACHES
Computation of Guided waves inside composites structures
1. Prediction of velocity of modes inside composites according to fiber’s orientations

SH0 (Horizontal displacement) S0 : Symetric mode A0 : Antisymetric mode

Unidirectional plies

Multi-ply composite Energy velocity curves

Slowness curves

Aerodatings, October 1st, 2013. CEA/CETIM

 HYBRID MODELING APPROACHES
2. Prediction of propagation of the GWs through a complex structures

Transmission of GW through a
stiffener

β
PhD L. Taupin, 2011

plate Arbitrary Plate

scatterer
Analytic Analytic
Finite
Elements
Reflection/Transmission through a stringer

R=0 T=1 A0 – 70° R=1 T=0

A0 – 50°
ux ux

uy uy

uz uz

Aerodatings, October 1st, 2013. CEA/CETIM

 OTHER TOPICS RELATED TO UT INSPECTION OF COMPOSITES
• (Self) Adaptive inspection of curved parts with phased arrays

1st shot After 3 iterations

Surface echo Surface echo

No backwall echo
backwall echo
(Demo on CEA-LIST booth)

• Connection to CAD description and mechanical analysis

Textile composites CAD parts

(K.U. Leuven) (3DS)Aerodatings, October 1st, 2013. CEA/CETIM
CONCLUSION (PART I)

Simulation of UT inspection of composites (curved / heterogeneous / anisotropic) using bulk or

guided waves :

• Help for understanding complex results

• Tool for optimising a UT method (probe + procedure)

Modeling approaches mostly depend of the complexity of the configuration :

• Semi-analytical approaches on homogenized anisotropic parts :

• Hybrid coupling method (combination of semi-analytical/numerical techniques) :

• These models have been validated through experimental tests

• Composite damages and flaws, 3D textile are under investigation

Aerodatings, October 1st, 2013. CEA/CETIM

PART II : THE CAPME’UP PROJECT
 THE CAPME’UP PROJECT
CAPME’UP

•MAIN OBJECTIVE : TO MAKE INNOVATIVE NDE TOOLS AVAILABLE TO SMES

AND MID-SIZE GROUPS
•TWO INVOLVED CARNOT INSTITUTES :

Aerodatings, October 1st, 2013. CEA/CETIM

 THE CAPME’UP PROJECT

To effectively implement innovative NDT in your business:

NDT platforms have been set up to facilitate investment decisions of

TPE/PME/ETI:
Welcoming place to conduct industrial testing, feasibility and
demonstrations:
• Platform “Of the future NDT", located at CEA / Saclay LIST
• Platform "Innovative NDT" located at CETIM in Senlis

Simulation tools for ultrasonic inspection, adapted to the needs and

practices of PMEs / ETI are in development:
• Smart CIVA dedicated " Phased Arrays ": Optimization of parameters and
settings of phased array ultrasonic probe.
• Smart CIVA dedicated "Weld Inspection": Optimization and validation of a
weld inspection according to the weld and researched flaws.

http://www.capmeup.fr

Aerodatings, October 1st, 2013. CEA/CETIM

 Aerodatings –Yutz October 1st 2013

Part III (CETIM) : Innovative

NDT methods for composites
Phased array ultrasonics
Thermography
Computed X-ray tomography

H. Walaszek
sqr@cetim.fr 33344673682
henri.walaszek@cetim.fr
 Page 20

CETIM – EPI department

Various and high level means for NDT detection:

traditional methods
(PT, MT, RT, US, ACFM…)
advanced methods
(phased array UT…)
guided waves
acoustic emission
visual inspection(VT GNV)
NDT modelisation, CIVA software
Active thermography
X ray computed tomography
GNV VT
development of NDT methods adapted to meet the need of
customer

NDT Operators certified COFREND and COSAC

 Defects/non destructive methods: the
choice

Bad fibre orientation, lack of fibre

Voids, microporosities
Xrays, C.T.
Inclusions
Water in honeycomb, crush Ultrasonics, Thermal IR
Contaminations
Délaminations, disbonding (skin/core) Shearography,
Core crush taping, Resonance
testing

Discontinuities evoluting during a

mechanical/thermal stress
Acoustic emission
 Page 22

Technological context

Thanks to recent technological evolutions

Digital and data processing techniques are more powerfull
These technologies are implemented in NDT equipment and affordable

Many NDT equipment integrate image display and processing

Enable global view of the component beeing inspected
Make easier result interpretation
Traceability and data storage are enhanced

Application:
Testing of impact-damaged composite plates with three imaging
methods
Phased array Ultrasonics
ActiveThermal Infrared
X ray computed tomography
 page 23

Application of three methods

to dammaged parts

Presentation of the methods used

 Page 24

Phased array ultrasonics

Principles

Transposal from medical echography to NDT

Ultrasonics in medicine….. and Non destructive testing…

Now, industrial equipments are available for NDT

 Page 25

Phased array ultrasonics: principle

Principes

Consists in dividing the transducer in many elementary piezo

elements

Time delay application on the different elements:

Angle beam steering
Controled Beam focusing
Focus motion without physical motion)

Incrément
de
balayage

Traducteur monoélément Traducteur multiéléments

2 balayages mécaniques 1 balayage mécanique
+ balayage électronique linéaire
 Phased array ultrasonics: Page 26

UT PA Data
presentation presentation of acquisitions

A-scan presentation

C-scan presentation
Cscan
B-scan et D-scan presentation

Encoder

0 x
Cscan Bscan Dscan
Ascan
Dscan Ascan

Imaging zone

Bscan
Phased array
probe Impacted CFRP
composite plate
analysis
 Application of phased array UT in
naval industry

Non destructive testing of a dammaged Delamination

mast

Backwall
echo
 Phased array applications in naval
industry
Naval applications

Contrôle d’un safran par ultrasons multiéléments

Avantages des multiéléments

Gain de productivité
Fiabilité du contrôle
Imagerie des anomalies détectées et donc traçabilité des résultats
 Applications on wide structures

3 D ultrasonic imaging
Needs adressed:
NDT of wide composite structures
Alternative to immersion technique
Prototype parts, limited series..
 Applications on wide structures

3 D imaging
NDT of a double curvature pannel
Pastilles

Délaminage

Scotchs

Zoom on a delamination
1,3
1m m

Global vue
 Page 31

Phased array ultrasonics

Limitations of phased array ultrasonic technique

Data volume storage
Skill of operators higher than with conventional UT
Advantages of phased array ultrasonic technique

High sensivity
Optimization of settings versus inspected zone
A phased array transducer reduces the number of probes needed
Reduce of time for inspection
replacement of mechanical scanning by electronic scanning
Easier data analysis
Comparison with CAD files, simulation
 Page 32
Examples of
heat excitation
Active thermal infrared
sources

Halogen
lamp

Flash
lamps

Ultrasonic
Source waves
 Page 33

Examples of Active thermal infrared

application

Marine application

t=
2,0s

t=
10,0s
Testing of a boat hull
Lack of resin penetration t=
(Excitation duration 20s) 30,0s
 Page 34

Active thermal infrared

Testing of impact damaged composites

15J impact on
opposite side/camera
Flash excitation on
camera side
Phase diagram
 Page 35

Active infrared thermography

Drawbacks of active infrared thermography

Inspection depth is limited according to thermal diffusivity of the
material
A few millimeters for monolithic material, more for honeycomb
Surface properties affect the inspection
Interpretation of data requires knowledge of thermal behaviour of the
material
Advantages of active infrared thermography
Global, non intrusive, contact-less and eco-friendly inspection
In some cases, IT could replace Penetrant Testing for example
Applicable to many material and kind of defects
Composite, metallic
Delamination, disbonding, crack, water infiltration, …
Wide range of excitation sources
Feasibility study is required to choose the best one
Allows to determine the shape and the depth of the defect
Temporal or frequency analysis
 Page 36

Principles
X-Ray Computed Tomography

Computed Tomography
Representation of an object with reconstructed slices from deported
measurement achieved outside of the object
Reconstruction 3D
X-Ray Images of transversal
Real Object Reconstruction
around 360° slices of the object
 Page 37

Equipment
characteristics
Computed tomography

Courtesy of
VJ Technologies

NDT Medical applications

applications
Type Nanofocus CT Microfocus CT Medical CT
Macrofocus CT system
Characteristics system system system

Energy max 180 keV 240 keV 150 to 600 keV 1 to 15 MeV 160 keV

Dmax object 120mm 200mm 1m >> 1m 1m

Resolution 0,5 to 10µm 1 to 50µm 0,1 to 0,5mm 0,5 to 1mm 0,1 to 0,5mm

0,8 – 1,5
Cost 250 – 500 k€ 250 – 500 k€ 250 – 800 M€ 1 – 3M€
M€*
 Page 38

Example of Computed tomography

application

Composite pipe

3D View

Axial slice

Sagittal slice
 Page 39

Computed Tomography

Drawbacks of X-ray Computed Tomography

Non-portable system
Final resolution depending on the object size
Acquisition and reconstruction duration (from 0,25 to 12h)
Amount of data to analyse (from 2 to 20Go)
Advantages of X-ray Computed Tomography
Non-sensitive to the defect orientation and material
3D defect reconstruction and location in the volume
Complex shape inspection
Comparison with CAD or others scans
Dimensional measurement
R&D applications, expertise, retro-engineering
 Testing of impact-damaged Page 40

composite plates

Application of three NDT methods to

detection and sizing of delamination in an
impact damaged part
 Testing of impact-damaged Page 41

composite plates

In aircraft industry
Impact test is often used for structural composite parts
dimensioning
– Impact test trials on standardized parts

Side cut of an impacted

composite part

Source :
(Servais, 2007)
 Testing of impact-damaged Page 42

composite plates

In aircraft industry
Many structural composite parts are dimensioned through impact
tests
– Impact tests trials on standardized parts

CETIM equipment: Impact machine dedicated to these tests

– Trials meeting standard AITM 1-0010 requirements

L= Monolythic epoxyde resin –carbon fiber

l = 100mm

150mm
Unidirectionals plies oriented 0°,+/- 45°
or 90°

Total thickness 3,0mm

Impact machine
available in CETIM
 Testing of impact-damaged Page 43

NDT means
composite plates
used
Flash location
Sample for front side
under test excitation

Flash location
for back side
excitation Thermal
camera
20cm 50cm

Phased array ultrasonics

Active thermal infrared with flash
excitation

X ray computed Tomograph

(CETIM/MONTUPET project Tomopic)
 Testing of impact-dammaged Page 44

Test part 15J composite plates

Sizing of indications

Phased
array
ultrasonics

Back wall
echo
recording Active thermal
infrared
Active thermal
-Phase
infrared
0,16Hz Back
side flash
- Phase
excitation after
0,16Hz Back
threesholding
side flash
excitation-
 Testing of impact-damaged Page 45

Test part 30J composite plates

Sizing of indications

Phased X ray computed

array tomography
ultrasonics
- Grey level minimum
- Backwall value detected in
echo the thickness
recording-

Active thermal
Active thermal
infrared
infrared
-Phase 0,16Hz
- Phase 0,16Hz
Back side flash
Back side flash
excitation after
excitation-
threesholding
-
Comparison of Testing of impact-damaged Page 46

the results composite plates

Indication sizing

Impact energy 15J 30J

LX LY LX
LY
Dimension (mm (mm (mm
(mm)
) ) )
Phased array
26,0 18,0 44,0 37,5
Ultrasonics
NDT
Active thermal
method 19,5 16,4 41,2 40,0
infrared
used
Computed
- - 46,0 47,0
tomography
 Testing of impact-damaged Page 47

30J
composite plates
Sample test

delamination signature evolution versus depth in the part

X ray computed
tomography
Impacted side Opposite side /impact

Active thermal
infrared*
*- phase at different frequencies ,
front face flash
 Testing of impact-damaged Page 48

30J composite plates

Sample test
delamination signature evolution versus depth in the part
30J sample tridimensional tomographic analysis
Plan XY

Impact

Plan XZ

Impact
 Page 49

Conclusions & Perspectives

Non Destructive Inspection using imaging technique have many

advantages
Global eyesight of the inspected component
Easier interpretation
Improvement of traceability and storage of the data
Facilitates the communication between NDT provider and customer

Imaging techniques enable comparison of Non destructive analysis by

different methods, using different physical laws
Sizing of delamination gives comparable results
The methods used enable study of delamination state step by step, from
the surface to back side
Interest for the comprehension of delamination progress in the impacted
components?
Ultrasonic inspection would benefit of the simulation:
Better understanding of the propagation
Optimization of the part at conception stage
Reduction of the need of prototype parts
Thank you for your attention

Aerodatings, October 1st, 2013. CEA/CETIM