NDI(Non Destructive Inspection) Composites

NDI inspection is an inspection technique used to analyze properties of a material, component, system without causing damage. Different terms used to describe this technology.

Non-destructive examination (NDE) Non-destructive inspection (NDI) Non-destructive evaluation (NDE)

NDI methods may rely upon the use of electro magnetic radiation, sound and inherent properties of materials to examine. NDI inspection is widely used for examination of composites, Since the attenuation (Scattering and absorption of sound waves) in composites is more less frequency of 5 MHZ or less is used for inspection. For UD plies spaced at 8 plies/mm the frequency used for inspection is about 12 MHZ The frequencies used for NDI inspection is decided based on practice. Most of the NDI techniques short pulses of ultra sound (few micro seconds) are passed into the composite materials from a transmitter end and are reflected back from the surfaces of flaws (defects) and received at the receiver end.

Ultrasonic inspection technology

Pulse Echo transducer sends out a pulse of energy, to normal of surface . The pulse is reflected from good matrix reinforcement boundaries, and boundaries associated with flaws, The position of flaw and size of flaw is determined by the total pulse travel time and detected amplitude

Through Transmission

Reflections occur due to the presence of discontinuities and the surfaces of the test article. Reciver being placed on the opposite side of the component and facing the transmission probe. Compared to pulse echo there is no dead zone which means that flaw can be detected at all depth through the thickness of the part.

NDI inspection methodologies (In house) and defect identification

Inspection Techniques
Visual Inspection Tap test A scan

Type of identifiable defects

Delaminations over skin surfaces, Porosity (Visible), Visible inclusions, interply delaminations, skin-to-honeycomb disbonds (near side of non metallic cores), Fiber Breakout from Drilling Operations (Drilling, Counter sinking), Surface Depressions, Defects in corners and radius,

C scan-Squitter

C- Scan - Bubbler
Infrared

Surface Scratches, Surface Depressions on Bag side and Tool side, Surface Resin Ridges, Tedlar Wrinkles, Bondable Teflon Wrinkles, Missing, ResinRich Areas, Core Edge Depressions, Part War page, Honeycomb Core Node Bond Separation, Radius Bridging, Surface Resin, Foreign Material Detected by NDI, Surface Resin Starvation, Internal voids, Porosity
Thickness variation in parts, delaminations, Disbonds sandwich (Metallic cores),

NDI Techniques and their selection criteria

The major factors deciding selection of NDI inspections are Engineering Drawing/Manufacturing standards Machine parameters and capacities Part sizes Part types Part profile complexities

NDI Techniques (In house) and their selection criteria

The different factors for selecting NDI inspection for a part are listed below 1. Engineering drawing/ manufacturing process requirement Engineering drawing call out usually specifies NDI requirement for part When part drawing/Manufacturing document calls for below classes

BOEING Example 1: BAC 5317

Class A Visual inspection and instrumental NDI First cure of each production part Visual inspection and instrumental NDI each detail part and bond line after respective cures
Class B Visual inspection and instrumental NDI at designated locations in the Engineering drawing as per Boeing approved plan Class C Visual inspection and instrumental NDI for each production part according to the sampling plan approved by Boeing Class D Visual inspection of the production part

When no class is specified part should be inspected as per Class A

NDI Techniques - selection criteria

1.

Engineering drawing/ manufacturing process requirement

Example 2: BAC 5578

TYPES Type I Requires: (a) Visual and (b) dimensional inspection of each production part. Type II Requires: (a) Type I inspection and (b) instrumental NDI based on a sampling frequency equivalent to MILSTD1235 with an Average Outgoing Quality Limit (AOQL) of no greater than 1. Type III Requires: (a) Type I inspection and (b) instrumental NDI at locations designated on the Engineering drawing using a sampling frequency in accordance with Type II. Type IV Requires: (a) Type I inspection and (b) instrumental NDI on each production part.

NDI Techniques (In house) and their selection criteriaC SCAN SQUITTER
2. Machine parameters-

Machine operating parameters

Length Width 6.5 m 2.0 m

Height
Inspection speed Max. linear acceleration No of axes (X,Y,Z,A,B) 3D rotation/Limitation angles Transmission medium (Coupler) Mode of inspection Range of parts can be inspected Complexity Geometries can be inspected

2.5 m
1.67 m/s 1.5 m/s 10 A= +105 to -105 B= +180 to -180 Water Pulse echo and Through transmission Existing inspection- Through transmission Monolithic parts, sandwich parts, metallic (Skins), Ceramic skins e.t.c Flat, Semi curved, C shaped, S shaped, T shaped Part surface

NDI Techniques (In house) and their selection criteria Importance of part bunching in squitter Time study

Case 1 Scanning of single part - FACC part number FK13798 L=1.1M W=0.65M 1. 2. 3. A single part FK 13789 was given to squitter for scanning Machine was ruuned at 60 % of maximum speed. The overall scanning time for the above mentioned part was 51 Minutes.

Reason
Before attaining the maximum acceleration of the machine (Which is supposed to be attained at 6.5 m) the machine is decelerated immediately after scanning the part Width of = 0.65m Since the maximum speed of the machine is not utilized the overall inspection time is more.

Fig:2 Comment of the inspector in the inspection report

NDI Techniques (In house) and their selection criteria Importance of part bunching in squitter Time study

Case 2 Scanning of four parts bunched - FACC part number FK13798

1.
2. 3.

Four FK13798 parts were bunched together in the fixture

Machine ruuned at 60 % of maximum speed The overall inspection time for the machine was 63 mins

Reason In this case machine was ruuned at 60% of maximum speed Scanning length of the machine was 2.6m (Total width of 4 parts)

Even though maximum speed of the machine speed is not utilized

The total scanning time for 4 parts was less compared to scanning a single part. This study shows the importance of utilizing the maximum scanning length of the machine

Fig:3 Comment of the inspector in the inspection report

NDI Techniques (In house) and their selection criteria Fixture Study
The present fixture in Water jet using for programs excluding Boeing program is below Usable dimensions Length=6.2 m Width = 2.3 m Figure shows spirit- lower panels of 3 different sizes bunched in the fixture. Presently parts are scanned as per ship set requirement and plan Parts having same ref stds are bunched together. Almost 80 percentage of the fixture length is used in this bunching plan. Suitable orientation of the part in fixture also plays a major role in reducing overall inspection time

Concept of Lower panels bunched in existing fixture.

Scanning Times for Existing programs

Inspection timings for spirit parts in squitter

Part name

Dimensions (LXW) (Meters)

1.43x1.004

Total Inspection time (Setup time + M/C Time) (Mins)

60

Model

Panel 1 inbd

Panel 3 inbd

1.613X0.764

53

Panel 4 inbd

1.795X0.495

60

Panel 5 inbd

1.77X0.435

57

Panel 6 inbd

1.667X0.415

53

Panel 7 inbd

1.346X0.376

52

Dimensions courtesy: Estimation Timings Courtesy: SAP

Scanning Times for Existing programs

Inspection timings for spirit parts in squitter

Part name

Dimensions (LXW) (Meters)

Total Inspection time (Setup time + M/C Time) (Mins)

38

Model

Panel 1 outbd (Monolithic) Panel 1 mid outbd (Monolithic) Panel 3 outbd1 (Monolithic) Blow down Panel 1 Blow down Panel 2 Blow down Panel 3

1.032X0.223

01.825X0.51

53

0.418X0.117

20

0.372X0.233 0.367X0.233 0.422X0.218

24 24 24

NA

NA

Dimensions courtesy: Estimation Timings Courtesy: SAP

Scanning Times for Existing programs

Inspection timings for spirit parts in squitter

Part name
148A7406-7

Dimensions (LXW) (Meters)

Total Inspection time (Setup time + M/C Time) (Mins)

60

Model

148A7406-8

60

148A7406-10

60

Limitations and advantages of C scan Squitter

Limitations- C scan Squitter 1. 2. Parts having different ref stds cannot be bunched and inspected Machines maximum speed cannot be utilized, because the generated graphics will be having discrepancies and distortions 3. 4. Local areas where parts clamped are to be scanned again in A scan machine Inspection of holes less accurate and need to be inspected in A scan Advantages - C-scan Squitter
1. 2. High repetitive accuracy due to stable design. High accessibility due to slim construction of inspection mechanics (e.g., U-shapes, aircraft structural parts and exterior panels). 3. 4. 5. 6. Product-specific inspection area due to modular construction. Corrosion resistance Collision protection Automatic water control - adaptation to inspection head position.

NDI Techniques (In house) and their selection criteria C SCAN BUBBLER
Machine parameters- C-scan Bubbler

Machine operating parameters

Length Width Max thickness inspecting presently Inspection speed 6m 1m 22 mm Currently running at 70% of max speed Speed is determined based on trial and error method
(Clarity of image generated)

No of axes (X,Y,Z) Transmission medium (Coupler) Mode of inspection Range of parts can be inspected Complexity Geometries can be inspected Water Pulse echo and Through transmission Existing inspection- Pulse echo Monolithic parts, sandwich parts, metallic (Skins) Flat, T shaped, C shaped, L shape Part surface

NDI Techniques (In house) and their selection criteria

General inspection methodology (NADCAP requirement)

STEP 1: Inspection of reference standard

STEP 2 :Inspection of part

Usable Dimensions of C scan bubbler

STEP3: Re inspection of reference standard

1.0 M

REFERENCE STANDARD Scan 1, Scan 4

PART 1- Scan 2

PART 2-Scan 3

6.0 M

Scanning Times for Existing programs

Part name

Dimensions (LXW) (Meters)

0.376X0.288

Total Inspection time (Setup time + M/C Time) (Mins)

20

Model

STIFFNER-SPAR-HORIZ-UPPERINBD

TEE-SPLICE-UPPER-BUILD DOOR

1.32X0.253

50

STIFFENER UPR HORIZ

5.737X0.331

172

STIFF-SPAR-HORIZ-LWR

5.736X0.326

172

SPLICE-ANGLE-SPAR-FRONTLOWER FLAT SPLICE-ANGLE-SPAR-FRONTLOWER KINK

0.587X0.216

42

0.647X0.248

32

Scanning Times for Existing programs

Part name

Dimensions (LXW) (Meters)

3.828X0.195

Total Inspection time (Setup time + M/C Time) (Mins)

47

Model

LONGERON INBOARD-LH

SPLICE-WEB-SPAR-FRONT

0.688X0.532

42

Limitations and advantages of C scan Bubbler

Limitations- C scan Bubbler Low inspection speed Two times Inspection of ref. STD irrespective of part (NADCAP) requirement Re inspection of part in A scan for part hole and radius and un identifiable defects Maximum part size which can be inspected in existing fixture is 6.0 MX 1.0M, So part bunching is limited Limitations in scanning sandwich parts Advantages - C-scan Bubbler
Machine can inspect a part of Length 600MM Width 1,000M______thickness ____ MM, With present capacity

General notes