Non-Destructive Testing in the aerospace domain. NDT Expert experience

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1 Non-Destructive Testing in the aerospace domain NDT Expert experience Fernando SANTOS - NDT Expert, France

2 Contents 1. Summary 2. NDT Expert, presentation 3. The Engineering AT division 4. NDT Expert experience on the space sector 4.1 NDI on production/integration sites 4.2 NDI for feasibilitiy studies 4.3 NDI support for expertises 5. Conclusions

3 NDT Expert 1 - Summary Presentation of NDT Expert services and main objectives Engineering AT The role of the Engineering department for internal and external clients NDI support to production / integration sites NDT Expert activities for production and integration facilities for daily work NDI support to feasibility studies NDT Expert activities to support the feasability studies Procedure writing, choice of materials... NDI support for expertises NDT Expert activities on unexpected events, follow-up of suppliers, specific inspections... Conclusions Feedback on 16 years of activity

4 2 NDT Expert

5 Engineering AT : preparing the future 3 - Engineering AT High level expertises Engineering Engineering AT AT Technology transferts Research & Development Advanced technologies Innovative Techniques assessment Development industrialisation Customized solutions

6 3 - Engineering AT Fast and reliable inspection tools Ultrasound arrays Eddy current arrays (for corrosion and subsurface fatigue cracks) Digital X-ray (pulsed sources) Shearography for impact damage assessment (CFRP/sandwich structures) Infrared imaging by microwave excitation (CFRP/sandwich structures) Fast Assessment and Reporting Moireview (dents and rivet pull-in) Shapeview (shape measurement) Scratchview (in progress) Wireless scanning (in progress) Development of structural health monitoring systems Crack monitoring (eddy current foil sensors), Water ingress (microwave antennas), Impact (shock detector)

Fast and reliable inspection tools UT Phased

7 Fast and reliable inspection tools UT Phased array 3 - Engineering AT Real time Bscan imaging and Cscan imaging. Large volumes inspected without moving the probe. Easier detection and sizing of damages. Delaminations in composites. Crack detection at bore hole. Porosity and cracks in metallic parts.

8 Fast and reliable inspection tools Eddy current array 3 - Engineering AT Feasibility and procedure development for corrosion mapping and subsurface crack detection First deployment at Astrium ST, Aquitaine and Mureaux

Fast and reliable inspection tools Use of modeling

ultrasonic fields. Modelling of ultrasonic inspections.

To predict and assess: Probe choice and /or design.

9 Fast and reliable inspection tools Use of modeling tools (CIVA) 3 - Engineering AT Calculation of ultrasonic fields. Modelling of ultrasonic inspections. Modelling of Eddy current inspections. To predict and assess: Probe choice and /or design. Limits of use. Inspect ability. Definition of inspection conditions. Array lobes

10 Fast and reliable inspection tools Digital X-ray system for in-service applications 3 - Engineering AT 9.5mm lap joint with electro-eroded and fatigue cracks: zoomed image - fatigue crack of 0.1mm width

11 Fast and reliable inspection tools Digital X-ray system for in-service applications 3 - Engineering AT Exposition parameters (Exposure time and gain) Scanning area parameters (X, Y displacement) Software interface for X-ray detector displacement

Fast and reliable inspection tools Shearography Fast

Elevons - CFRP/Nomex Ailerons Wing tips - CFRP/foam

Rudder, Radome 3 - Engineering AT (disbonding,

12 Fast and reliable inspection tools Shearography Fast damage assessment Deployment: For what? Elevons - CFRP/Nomex Ailerons Wing tips - CFRP/foam Winglets Other results on representative samples: Rudder, Radome 3 - Engineering AT (disbonding, delamination and honeycomb cracking) (disbonding, delamination and foam cracking)

13 Fast and reliable inspection tools 3 - Engineering AT WISKit - Water Ingress Stimulation Kit Multi-frequency sequential excitation more even EM fields 40 W output power Off Stand by Test led Off Measure Buzzer Measuring led RF OUT

14 Fast and reliable inspection tools WISKit - Water Ingress Stimulation Kit 3 - Engineering AT Inspection performed with set-up on horizontal stabilizer (TBC) WISKIt with 2 connexions External view Antennas With conventional thermal excitation With microwave thermal excitation ELEVATOR

15 Fast Assessment and Reporting Moireview - Dent and rivet pull-in characterization 3 - Engineering AT Airbus (Filton, St. Nazaire, Toulouse), EADS ST, EC-D, Latecoere, Embraer

Fast Assessment and Reporting Shapeview Automatic shape inspection

Measurement Time : 1/1000 s Calculation Time :< 1 mn Portable and

: the measurement is made by the operator supporting the system by

16 Fast Assessment and Reporting Shapeview Automatic shape inspection system 3 - Engineering AT Specifications Size of the inspection area : 1 m X 0.75 m Accuracy : 50 µm Spatial resolution : 5 mm Working Distance : 1m Measurement Time : 1/1000 s Calculation Time :< 1 mn Portable and autonomous; power supply : batteries No need for any holder or tripod : the measurement is made by the operator supporting the system by hands Possibility to achieve measurements on bright surfaces with a reasonable sunlight (50 KLux) Tool for the A380 Enhanced Support -SDRM

Fast Assessment and Reporting ScratchView - Scratch

5 µm Spatial resolution : 2 µm laser line projection Laser

17 Fast Assessment and Reporting ScratchView - Scratch characterization tool 3 - Engineering AT Technical data: Weight : < 1.5 kg Dimensions : < 150 X 150 X 150 mm3 Accuracy in depth : 5 µm Spatial resolution : 2 µm laser line projection Laser Diode Camera Autonomous (battery powered) Fully portable Easy to use by non experimented operators. Specimen Scratch

Fast Assessment and Reporting Wireless scanning system (concept prototype) 3 - Engineering AT E/R Générateur US ou CF POSUS Récepteurs ultrasons Signal US ou CF

18 Fast Assessment and Reporting Wireless scanning system (concept prototype) 3 - Engineering AT E/R Générateur US ou CF POSUS Récepteurs ultrasons Signal US ou CF Valeurs des compteurs Impulsion de synchro PC Fast reporting US air émetteur PVDF US air Câbles de connexion. Traceability Sonde US ou CF Archiving for minor damages

19 3 - Engineering AT Development of structural health monitoring systems A Identification of scenarios for maintenance and cost benefit assessment NTM, MPD and AMM analysis B Development of sensors Eddy current foil sensors Microwave antennas Shock detector C - Implementation of sensors Technical note Physical implementation Follow-up

(decreasing aircraft DMC) 3 Monitoring of aircraft sensitive part (increase aircraft safety) 4 Follow-up of aircraft critical

20 Cost assessment on 4 maintenance scenarios 3 - Engineering AT Development of structural health monitoring systems 1 Replacement of conventional NDT inspection - (decreasing aircraft DMC) 2 Replacement of conventional NDT inspection (decreasing aircraft DMC) 3 Monitoring of aircraft sensitive part (increase aircraft safety) 4 Follow-up of aircraft critical zone (increase airline aircraft availability) A300 NTM A320 NTM A300 SB No compulsory inspection on landing gear doors

21 3 - Engineering AT Development of structural health monitoring systems Eddy current foil sensor for crack detection and monitoring Microwave antennas for water measurement and location inside sandwich structures Shock detector for impact characterization on composite structures

22 4. NDT Expert experience on the space sector 4.1 NDI on production/integration sites 4.2 NDI on feasibilitiy studies 4.3 NDI support for expertises

23 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites To be able to support industrials during ramp up periods or pre defined overload To be able to support industrials with short NDI capabilities To be able to support industrials on specific NDI requests Most of the recurrent work deals with X-ray and UT - Assessment of assembling process (RT and UT) - Assessment of disbonding on sandwich structures (ST and Resonance) - Assessment of dimensional values after manufacturing/assembling process (RT) - Assessment of structural damage after manufacturing process (UT)

24 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites X-ray control of cables integrity after assembly

25 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites 45,7 C Thermographic control of bonded heaters 30,4 C 30 35,1 C ,8 C ,4 C 29,3 C

26 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites X-ray control of cables integrity for thermistance integrity assessment

27 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites X-ray control of pyrotechnique separation nut for dimensional and assembling quality assessment

28 4 NDT Expert experience on the space sector 4.1 Support to production/integration sites Thermographic control of different waveguide components after assembling

29 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies To be able to choose the best method for a specific application To be able to provide clear information by defining inspection procedures Work on: - New materials and geometries (ceramics, polimers - New assembling processes (welding, bonding - Faster inspections -

30 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies Optimisation of X-ray inspection of satellite pipes Inspection radioscopique numérique d assemblage par brasure Faster and more reliable inspections

31 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies Inspection procedure for new assembling method

32 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies Development of inspection procedure for faster and more reliable control mation [µm\shear]

33 Ceramic SiC integrity control with: 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies - Dye penetrant - Ultrasound ep=3 mm - X-ray α α

shearographique (Système optique + laser) Faisceau Laser Lampe halogène Objet Décollement Renfort

34 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies Infrared imaging and shearography study on CFRP assemblies Tête shearographique (Système optique + laser) Faisceau Laser Lampe halogène Objet Décollement Renfort carbone EP=2.4 Renfort carbone EP=0.3 Semelle carbone EP=0.3 Colle Redux 312 L Colle Redux 312 L Colle Redux 312 UUL NIDA 6-20 NIDA 3-20 Traitement d images

35 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies X-ray and UT investigation on AL-Ti diffusion assembly structures

36 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies UT investigation on Steel/Cobalt welding integrity «Detection of lack of fusion» Conclusions and recommendations: «La méthode utilisée devrait permettre de détecter des manques de fusion à l interface tôle-métal d apport. Une validation complète de la soudure nécessitera la réalisation de trous à fond plat situés à l interface acier-métal d apport et d un diamètre équivalent au plus petit défaut à détecter. Remarque : avec les réglages utilisés, le trou à fond plat de diamètre 1.2mm situé à une profondeur de 30mm (bloc aluminium) est détecté.»

Axe sonde Sens propagation uultrason Relais plexiglass Tube carbone bobiné Disbonding Sound area

37 4 NDT Expert experience on the space sector 4.2 Support to feasibility studies Inspection investigation on C-C tubes by UTPA Sonde ultrasonore R 47 Axe sonde Sens propagation uultrason Relais plexiglass Tube carbone bobiné Disbonding Sound area Equipement : - OMNISCAN MX Version 1.0B3 Probe : 5MHZ 64 éléments Relais SI1N0L. Reflection mode Defects to detect: Disbondings between Al skin and Al honeycomb

38 4 NDT Expert experience on the space sector 4.3 Support to expertises To be able to make a critical statement on the most diverse structural configurations Work on: - Follow-up of suppliers NDI capabilities - Expertises after unexpected events (impacts ) - Expertises following reworking/repairs - Expertises after malfunctioning -

subcontractor: - Audit, due to poor NDI assessment by OEM - Recommendations to

39 4 NDT Expert experience on the space sector 4.3 Support to expertises Zone droite de la «pressure vessel» : Follow-up of subcontractor: - Audit, due to poor NDI assessment by OEM - Recommendations to improve NDI methods - Analyze of improvements Défaut d usinage ou d ajustement pouvant entraîner une soudure non acceptable

40 4 NDT Expert experience on the space sector 4.3 Support to expertises CFRP ultrasound inspection for delamination around skin drilling Inspection of area surrounding hole Inspection with hole protected by watertightness insert Geometrical constraints - Probe dimension (diamètre 7.5mm) - Active probe diameter (diamètre 3mm) Area close to the hole (~2mm to 2,5 mm) it cannot be inspected Precise and well defined inspection constraints for clear damage assessment

41 4 NDT Expert experience on the space sector 4.3 Support to expertises Foils integrity X-ray inspection of a Li-Ion battery module Inspected cells film Bypass X-ray source

rotating probes after reworking Area inspected by rotating probe

42 4 NDT Expert experience on the space sector 4.3 Support to expertises Eddy current inspection by pencil and rotating probes after reworking Area inspected by rotating probe Front flange Dewar fixation Inspected areas by pencil probe For crack detection open to the surface.

43 4 NDT Expert experience on the space sector 4.3 Support to expertises X-ray inspection of tube after laser welding failure Investigation allowed to: - Detect failures at tube weldings - Probable causes are: - Lack of penetration - Floating welding width - Unsatisfying adjustment between tube and base structure

inspection on electrical cable to detect thickness

- Ultrasound inspection on CFRP tube after impact -

44 4 NDT Expert experience on the space sector 4.3 Support to expertises Other expertises: - X-ray inspection on electrical cable to detect thickness reduction - Shearography inspection on antenna after impact - Ultrasound inspection on CFRP tube after impact - Shearography inspection on bonded brackets after machining - Ultrasound inspection on metallic frames

45 5 Conclusions Major difficulties: Most of the times industrials only have general procedures Work with no procedure Work without calibration standard Different configurations of satellites Major NDT Expert assets: - Deep knowledge of all NDI methods and techniques - Work force with several Level 3 techniciens and PhD (experimental mechanics, material science, optics, ultrasounds, thermography) - Flexibility and reactivity - Different equipments adapted to expertises full field techniques, allow to work without calibration standard comparison between sound and damaged area (Shearography, thermography, X-rays) - R&D activity through national, european and EADS research programs

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