Modelling of small CFRP aerostructure parts for X-ray imaging simulation

Purpose The aim is to develop a realistic computational model of Carbon Fiber Reinforced Polymer (CFRP) structures dedicated for in-silico investigations of the use of X-ray based imaging techniques as non-destructive testing (NDT) of CFRP parts. Design/methodology/approach CFRPs contain layers of carbon-fibers bundles within resin. Bundles’ orientation in the different layers is arranged with respect to each other at a well-defined primary direction. In our model, the bundle was simulated as a circular cylinder. The resulted model is a stack of layers of unidirectional bundles having orientation of 0°/90°/45°/-45°. Two CFRP structures were modelled: a flat CFRP part and a real shaped CFRP clip. A porous layer and non-carbon fibers were inserted within each model, respectively. X-ray projection images were generated with a dedicated simulation program. Three setups were investigated: Radiography, Tomosynthesis and Cone-Beam CT (CBCT). Findings Results showed that porosity and non-carbon fibers were visible with all x-ray based techniques. Tomosynthesis and CBCT, however, provide higher quality image of defects. Practical implications The CFRP computational model is a valuable tool in design, testing and optimisation phase of X-ray based imaging techniques for use in NDT of composite materials. Simulated images are generated within a short time; thus results from virtual optimisation and testing are obtained very fast and at low cost. Originality/value An innovative computational model of CFRP structures, dedicated for X-ray imaging simulations, has been developed. The model is characterised by simplicity in its creation and realistic visual appearance of the produced X-ray images.