Non-destructive Evaluation of Aircraft Structural Components - Engineering Assignment Help

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Executive Summary

The rapid rate of advancement in materials and manufacturing technologies ensures an ongoing requirement for improved non-destructive evaluation (NDE) techniques. To cater for known shortfalls in contemporary NDE capability, damage tolerance assessments which underpin the structural airworthiness of many air platforms are often made deliberately conservative. Thus, a strong motivation exists for the development of enhanced inspection capabilities that may offer a basis for more efficient structural management.
A strong impetus already exists in relation to the inspection of tightly closed cracks in metallic components and kissing bonds in composite structures which are often difficult to detect using conventional NDE methodologies. Sonic thermography shows some promise in these and other difficult applications. It involves injecting a specimen with high frequency acoustic waves. These waves radiate through the specimen, interacting with flaws to produce lateral relative motion at the flaw surfaces. In the presence of a compressive stress this motion gives rise to frictional heating which in turn produces a thermal signature.

This report documents some of the applications of a sonic thermographic facility de- veloped by the Defence Science and Technology Organisation (DSTO) to the detection of defects in a variety of aircraft structural components and composite materials. The results confirm that sonic thermography has the potential to assist the Australian Defence Force (ADF) in solving some difficult inspection problems and could therefore help in reducing through life support costs for aircraft.

1 Experimental setup showing the specimen, acoustic horn and infrared camera. 2
2 Dimensions and layup of a C/Ep composite specimen with embedded teflon inserts. Measurements are in mm. . . . . . . . . . . . . . . . . . . . . . . . . 4
3 From top to bottom, ST raw, PPT and PCT2 results and flash PPT showing signatures from the Teflon inserts. . . . . . . . . . . . . . . . . . . . . . . . . 6
4 (a) Diagram of the insert positions embedded in the mid plane, 50% of the total thickness of the laminate and in the near surface, 15% of the total thick- ness, (b) photograph of the specimen, the outline in red shows the inspection area and (c) through-transmission ultrasound image showing insert locations in specimens A, B and C, from the reverse side of the specimens, as indicated (courtesy CRC-ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 ST inspection of the thin film insert specimens from front face. Specimens A, B and C are indicated, and the PPT and PCT1−5 results, are shown. The defect positions for specimens A and B are shown to the right of the thermographs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 FT inspection of the thin film insert specimens. Specimens A, B and C are indicated, and the PPT, and PCT results for modes 2 and 4, are shown. The defect positions for specimens A and B are shown to the right of the thermographs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 ST inspection of the reverse face of the thin film delamination specimens showing PCT2 and PCT4 results for specimen A and PCT4 and PCT5 results for specimen B as indicated. The defect positions for specimens A and B are shown to the right of the thermographs. . . . . . . . . . . . . . . . . . . . . . 11
8 Diagram of the skin-frame flange panel showing flange 1 as the bonded and riveted frame and flange 2 as the bonded frame. . . . . . . . . . . . . . . . . . 12

9 (a) Damage map, (b) ST result (PCT3) and (c) FT result of specimen 1. The results shown in (b) and (c) are of the respective thermographs which have been superimposed with a photograph of the panel. In (a) the coloured circles correspond to the vaseline contamination in the bondline, red crossesindicate impact fractures and areas marked by the red outline indicate damage disclosed by C-scans. In (b) the arrow indicates vibrational mode patterns due to anelastic heating. Note that the blue circles in (c) (an example of which is indicated by the arrow) are markers used for alignment of the thermographic images.

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