Robotized Infrared Thermography for the inspection of composite components : Basic Theory and Applications in the European Industry

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1 Robotized Infrared Thermography for the inspection of composite components : Basic Theory and Applications in the European Industry office@visiooimage.com notes: animations/videos can not be printed. St-Hubert, 11 octobre, 2018 par Pierre Servais, PhD Matthieu Klein, MSEE Clemente Ibarra, PhD

2 Outline 1. Introduction to infrared thermography for NDT 2. Line Scan Thermography LST 3. Composite Testing in the European Aircraft Manufacturing 4. Conclusions 2

3 1. Introduction: Infrared Thermography for NDT Infrared (IR) radiation William Herschel 3

4 1. Introduction: Infrared Thermography for NDT IR in the Electromagnetic Spectrum c = l x f E = h x f h = x Js 4

5 1. Introduction: Infrared Thermography for NDT Classic experimental setup for NDT: Pulsed Thermography (PT) Specimen before heating Cold image 5

6 1. Introduction: Infrared Thermography for NDT Classic experimental setup for NDT: Pulsed Thermography (PT) Specimen after heating 6

7 1. Introduction: Infrared Thermography for NDT PT - Thermal response 7

8 1. Introduction: Infrared Thermography for NDT PT Scenario 8

9 1. Introduction: Infrared Thermography for NDT Signal processing techniques for IRT Thermal contrast-based techniques (max. contrast, FWHM, etc.) Differential Absolute Contrast, DAC t T T ( t) T t Thermographic Signal Reconstruction, TSR Principal Component Thermography, PCT Pulsed Phase Thermography, PPT T( t) T ( t) T ( t) ln Q e 1 2 T ln ln t A=USV T F n dac t d d N 1 k 0 T t S a ( j2 nk N) k t exp Ren Imn 9

10 1. Introduction: Infrared Thermography for NDT Data processing: Pulsed Phase Thermography (PPT) Thermal Contrast Methods t = s FT f = Hz f = Hz t = s Pulsed Phase Thermography (a) (b) (c) 10

11 1. Introduction: Infrared Thermography for NDT PPT

12 2. Line Scan Thermography LST Experimental setup for LST and data acquisition / reconstruction 12

13 2. Line Scan Thermography LST LST Scenario 13

14 2. Line Scan Thermography LST Line-scan ECT 14

15 3: Industrial Test Cases for LST at Sonaca, Belgium P. Servais, Aerospace Engineer Doctor in NDT Level 3 PT MT ET UT RT IRT Responsible level 3 NDT for Sonaca, Sabca, Asco, Safran China

16 3: Industrial Test Cases for LST at Sonaca, Belgium High rise of composite parts NDT 16

17 3: Industrial Test Cases for LST at Sonaca, Belgium Sonaca Group : 2500 personnes + récemment rachat LMI (4000 personnes) Présent en Belgique, Canada, Brésil, Chine et en Roumanie Conçoit et produit des pièces de structures aéronautiques pour Airbus, Embraer, Bombardier, Dassault,. 17

18 3: Industrial Test Cases for LST at Sonaca, Belgium Pièces composites : SLATS Bords d attaque Pièce composite Pièces métaliques

19 3: Industrial Test Cases for LST at Sonaca, Belgium Pièces composites : WINGS Longueur : +/- 8m Flaps

pour le contrôle de pièce composite : Cuve d immersion et Robot

20 3: Industrial Test Cases for LST at Sonaca, Belgium Avant : contrôle par Ultrason (immersion ou contact) Équipement NDT pour le contrôle de pièce composite : Cuve d immersion et Robot pour le contrôle NDT Coût : +/- 1M - temps d inspection : de 15 min à 2h

21 3: Industrial Test Cases for LST at Sonaca, Belgium Recording of IR live video 21

22 3: Industrial Test Cases for LST at Sonaca, Belgium LST : reconstruction des données (animation)

23 3: Industrial Test Cases for LST at Sonaca, Belgium LST : industrialisation

24 3: Industrial Test Cases for LST at Sonaca, Belgium LST : Nid d abeille Linescan Thermo - 2 minutes Scan Ultrasonic C-scans : 30 minutes

3 m Structure : peaux en carbone collées sur un

25 3: Industrial Test Cases for LST at Sonaca, Belgium LST : Fairing Flap Fairing ( prototype ) avec défauts artificiels : Taille : 2 m x 0.5 m x 0.3 m Structure : peaux en carbone collées sur un nid d abeille Forme très étroite et courbe => contrôle est difficile avec les équipements actuels

26 3: Industrial Test Cases for LST at Sonaca LST : Fairing Flap Fairing ( prototype ) avec défauts artificiels : 26

27 3: Industrial Test Cases for LST at Sonaca Défauts collage Nida Fairing - multiméthode LINESCAN IRT - Visiooimage Flap Track Fairing Digital Xray DeReo 40cm Xris 27

28 3: Industrial Test Cases for LST at Sonaca, Belgium LST : Renfort Pièce monolithique épaisseur 2 mm Forme complexe Contrôle partiel en UT en manuel

29 3: Industrial Test Cases for LST at Sonaca, Belgium LST : Renfort

30 3: Industrial Test Cases for LST at Sonaca, Belgium Porosity panels - Simulations Typical IRT scan result showing 3 porous zones detectable (from above 6dB) :

31 4. Conclusions 1. LST is a new NDT technique from IRT well dedicated to complex composite geometries 2. LST is very performant on honeycomb structure and thin monolithic parts 3. No problem for high curvature or non parallel surfaces 4. LST is at least 5 times quicker than Ultrasonic Testing 5. No problem of coupling, no water consumption, no water heat/pollution/filtering 6. Use of latest post processing digital filtering based on video acquisition 7. IR camera and heater have now lower cost than phased array system Thanks to CRIAQ, SKYWIN, SONACA and WAN to open international Belgium-Canada collaboration 31

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