Improvement in the Quantification of Foreign Object Defects in Carbon Fiber Laminates Using Immersion Pulse-Echo Ultrasound
This research presents a new technique using pulse echo ultrasound for sizing foreign objects within carbon fiber laminates. Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur...
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description | This research presents a new technique using pulse echo ultrasound for sizing foreign objects within carbon fiber laminates. Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur within a carbon fiber laminates, causing waste, either in the discarding of failed parts or the overdesign of the initial part to account for these anticipated and undetected errors. One such manufacturing defect is the occurrence of a foreign object within the laminate. This defect will lead to a localized weakness within the laminate including, but not limited to, stress risers, delamination, and catastrophic failure. This paper presents a method to analyze high-resolution c-scan full waveform captured data to automatically capture the geometry of the foreign object with minimal user inputs without a-priori knowledge of the shape of the defect. This paper analyzes twelve samples, each a twelve-lamina carbon fiber laminate. Foreign objects are made from polytetrafluoroethylene (PTFE) measuring 0.05 mm (0.002 in.) thick and ranging in diameter from 12.7 mm (0.5 in) to 1.588 mm (0.0625 in), are placed within the laminates during fabrication at varying depths. The samples are analyzed with a custom high-resolution c-scan system and smoothing, and edge detection methods are applied to the collected c-scan data. Results are presented on the sizing of the foreign objects with an average error of 6% of the true area, and an average absolute difference in the estimation of the diameter of 0.1 mm (0.004 in), an improvement over recently presented ultrasonic methods by a factor of three. |
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Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur within a carbon fiber laminates, causing waste, either in the discarding of failed parts or the overdesign of the initial part to account for these anticipated and undetected errors. One such manufacturing defect is the occurrence of a foreign object within the laminate. This defect will lead to a localized weakness within the laminate including, but not limited to, stress risers, delamination, and catastrophic failure. This paper presents a method to analyze high-resolution c-scan full waveform captured data to automatically capture the geometry of the foreign object with minimal user inputs without a-priori knowledge of the shape of the defect. This paper analyzes twelve samples, each a twelve-lamina carbon fiber laminate. Foreign objects are made from polytetrafluoroethylene (PTFE) measuring 0.05 mm (0.002 in.) thick and ranging in diameter from 12.7 mm (0.5 in) to 1.588 mm (0.0625 in), are placed within the laminates during fabrication at varying depths. The samples are analyzed with a custom high-resolution c-scan system and smoothing, and edge detection methods are applied to the collected c-scan data. Results are presented on the sizing of the foreign objects with an average error of 6% of the true area, and an average absolute difference in the estimation of the diameter of 0.1 mm (0.004 in), an improvement over recently presented ultrasonic methods by a factor of three.</description><identifier>ISSN: 1996-1944</identifier><identifier>EISSN: 1996-1944</identifier><identifier>DOI: 10.3390/ma14112919</identifier><identifier>PMID: 34071565</identifier><language>eng</language><publisher>Basel: MDPI AG</publisher><subject>Algorithms ; Carbon fibers ; Catastrophic failure analysis ; Composite materials ; Defects ; Diameters ; Edge detection ; High resolution ; Laminates ; Manufacturing ; Manufacturing defects ; Measurement techniques ; Neural networks ; Polytetrafluoroethylene ; Risers ; Sizing ; Stress concentration ; Ultrasonic imaging ; Ultrasonic methods ; Ultrasonic testing ; Waveforms ; Wavelet transforms</subject><ispartof>Materials, 2021-05, Vol.14 (11), p.2919</ispartof><rights>2021 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). 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Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur within a carbon fiber laminates, causing waste, either in the discarding of failed parts or the overdesign of the initial part to account for these anticipated and undetected errors. One such manufacturing defect is the occurrence of a foreign object within the laminate. This defect will lead to a localized weakness within the laminate including, but not limited to, stress risers, delamination, and catastrophic failure. This paper presents a method to analyze high-resolution c-scan full waveform captured data to automatically capture the geometry of the foreign object with minimal user inputs without a-priori knowledge of the shape of the defect. This paper analyzes twelve samples, each a twelve-lamina carbon fiber laminate. Foreign objects are made from polytetrafluoroethylene (PTFE) measuring 0.05 mm (0.002 in.) thick and ranging in diameter from 12.7 mm (0.5 in) to 1.588 mm (0.0625 in), are placed within the laminates during fabrication at varying depths. The samples are analyzed with a custom high-resolution c-scan system and smoothing, and edge detection methods are applied to the collected c-scan data. Results are presented on the sizing of the foreign objects with an average error of 6% of the true area, and an average absolute difference in the estimation of the diameter of 0.1 mm (0.004 in), an improvement over recently presented ultrasonic methods by a factor of three.</description><subject>Algorithms</subject><subject>Carbon fibers</subject><subject>Catastrophic failure analysis</subject><subject>Composite materials</subject><subject>Defects</subject><subject>Diameters</subject><subject>Edge detection</subject><subject>High resolution</subject><subject>Laminates</subject><subject>Manufacturing</subject><subject>Manufacturing defects</subject><subject>Measurement techniques</subject><subject>Neural networks</subject><subject>Polytetrafluoroethylene</subject><subject>Risers</subject><subject>Sizing</subject><subject>Stress concentration</subject><subject>Ultrasonic imaging</subject><subject>Ultrasonic methods</subject><subject>Ultrasonic testing</subject><subject>Waveforms</subject><subject>Wavelet transforms</subject><issn>1996-1944</issn><issn>1996-1944</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2021</creationdate><recordtype>article</recordtype><sourceid>BENPR</sourceid><recordid>eNpdkdFqHCEUhqW0NCHNTZ9AyE0pTDKOo6s3hbLJJgsLaSB7LY57Ztdl1K06gZCXj0NCk9Sbo-d8fPhzEPpO6nNKZX3hNGkJaSSRn9AxkZJXRLbt53f3I3Sa0r4uh1IiGvkVHdG2nhHG2TF6WrpDDA_gwGdsPc47wHej9tn21uhsg8ehx4sQwW49vu32YDK-hL6UNPFzHbvCLGwHEa-0s15nSHidrN_ipXMQ0-T4Mw4JqiuzC3g95KhTGP3mG_rS69I_fa0naL24up_fVKvb6-X896oyVNBcdVIzzusOGiEaQWu6kYbLjnFaQgtDmZaE80ZOLyaAsNr0dEZM3_QtE3RDT9CvF-9h7BxsTIka9aAO0TodH1XQVn2ceLtT2_CgRDG2M14EP14FMfwdIWXlbDIwDNpDGJNqGOUt54Kwgp79h-7DGH2JN1FS0pkkolA_XygTQ0oR-n-fIbWa1qre1kqfAXM0k2o</recordid><startdate>20210528</startdate><enddate>20210528</enddate><creator>Blackman, Nathaniel J.</creator><creator>Jack, David A.</creator><creator>Blandford, Benjamin M.</creator><general>MDPI AG</general><general>MDPI</general><scope>AAYXX</scope><scope>CITATION</scope><scope>7SR</scope><scope>8FD</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>ABUWG</scope><scope>AFKRA</scope><scope>AZQEC</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>D1I</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>JG9</scope><scope>KB.</scope><scope>PDBOC</scope><scope>PIMPY</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>7X8</scope><scope>5PM</scope><orcidid>https://orcid.org/0000-0001-7199-0556</orcidid></search><sort><creationdate>20210528</creationdate><title>Improvement in the Quantification of Foreign Object Defects in Carbon Fiber Laminates Using Immersion Pulse-Echo Ultrasound</title><author>Blackman, Nathaniel J. ; Jack, David A. ; Blandford, Benjamin M.</author></sort><facets><frbrtype>5</frbrtype><frbrgroupid>cdi_FETCH-LOGICAL-c383t-b9a5660be28828303d9c69b5639198c35a916629919858e150cf371cf2f4583d3</frbrgroupid><rsrctype>articles</rsrctype><prefilter>articles</prefilter><language>eng</language><creationdate>2021</creationdate><topic>Algorithms</topic><topic>Carbon fibers</topic><topic>Catastrophic failure analysis</topic><topic>Composite materials</topic><topic>Defects</topic><topic>Diameters</topic><topic>Edge detection</topic><topic>High resolution</topic><topic>Laminates</topic><topic>Manufacturing</topic><topic>Manufacturing defects</topic><topic>Measurement techniques</topic><topic>Neural networks</topic><topic>Polytetrafluoroethylene</topic><topic>Risers</topic><topic>Sizing</topic><topic>Stress concentration</topic><topic>Ultrasonic imaging</topic><topic>Ultrasonic methods</topic><topic>Ultrasonic testing</topic><topic>Waveforms</topic><topic>Wavelet transforms</topic><toplevel>peer_reviewed</toplevel><toplevel>online_resources</toplevel><creatorcontrib>Blackman, Nathaniel J.</creatorcontrib><creatorcontrib>Jack, David A.</creatorcontrib><creatorcontrib>Blandford, Benjamin M.</creatorcontrib><collection>CrossRef</collection><collection>Engineered Materials Abstracts</collection><collection>Technology Research Database</collection><collection>ProQuest SciTech Collection</collection><collection>ProQuest Technology Collection</collection><collection>Materials Science & Engineering Collection</collection><collection>ProQuest Central (Alumni Edition)</collection><collection>ProQuest Central UK/Ireland</collection><collection>ProQuest Central Essentials</collection><collection>ProQuest Central</collection><collection>Technology Collection</collection><collection>ProQuest One Community College</collection><collection>ProQuest Materials Science Collection</collection><collection>ProQuest Central Korea</collection><collection>SciTech Premium Collection</collection><collection>Materials Research Database</collection><collection>Materials Science Database</collection><collection>Materials Science Collection</collection><collection>Publicly Available Content Database</collection><collection>ProQuest One Academic Eastern Edition (DO NOT USE)</collection><collection>ProQuest One Academic</collection><collection>ProQuest One Academic UKI Edition</collection><collection>ProQuest Central China</collection><collection>MEDLINE - Academic</collection><collection>PubMed Central (Full Participant titles)</collection><jtitle>Materials</jtitle></facets><delivery><delcategory>Remote Search Resource</delcategory><fulltext>fulltext</fulltext></delivery><addata><au>Blackman, Nathaniel J.</au><au>Jack, David A.</au><au>Blandford, Benjamin M.</au><format>journal</format><genre>article</genre><ristype>JOUR</ristype><atitle>Improvement in the Quantification of Foreign Object Defects in Carbon Fiber Laminates Using Immersion Pulse-Echo Ultrasound</atitle><jtitle>Materials</jtitle><date>2021-05-28</date><risdate>2021</risdate><volume>14</volume><issue>11</issue><spage>2919</spage><pages>2919-</pages><issn>1996-1944</issn><eissn>1996-1944</eissn><abstract>This research presents a new technique using pulse echo ultrasound for sizing foreign objects within carbon fiber laminates. Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur within a carbon fiber laminates, causing waste, either in the discarding of failed parts or the overdesign of the initial part to account for these anticipated and undetected errors. One such manufacturing defect is the occurrence of a foreign object within the laminate. This defect will lead to a localized weakness within the laminate including, but not limited to, stress risers, delamination, and catastrophic failure. This paper presents a method to analyze high-resolution c-scan full waveform captured data to automatically capture the geometry of the foreign object with minimal user inputs without a-priori knowledge of the shape of the defect. This paper analyzes twelve samples, each a twelve-lamina carbon fiber laminate. Foreign objects are made from polytetrafluoroethylene (PTFE) measuring 0.05 mm (0.002 in.) thick and ranging in diameter from 12.7 mm (0.5 in) to 1.588 mm (0.0625 in), are placed within the laminates during fabrication at varying depths. The samples are analyzed with a custom high-resolution c-scan system and smoothing, and edge detection methods are applied to the collected c-scan data. Results are presented on the sizing of the foreign objects with an average error of 6% of the true area, and an average absolute difference in the estimation of the diameter of 0.1 mm (0.004 in), an improvement over recently presented ultrasonic methods by a factor of three.</abstract><cop>Basel</cop><pub>MDPI AG</pub><pmid>34071565</pmid><doi>10.3390/ma14112919</doi><orcidid>https://orcid.org/0000-0001-7199-0556</orcidid><oa>free_for_read</oa></addata></record> |
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subjects | Algorithms Carbon fibers Catastrophic failure analysis Composite materials Defects Diameters Edge detection High resolution Laminates Manufacturing Manufacturing defects Measurement techniques Neural networks Polytetrafluoroethylene Risers Sizing Stress concentration Ultrasonic imaging Ultrasonic methods Ultrasonic testing Waveforms Wavelet transforms |
title | Improvement in the Quantification of Foreign Object Defects in Carbon Fiber Laminates Using Immersion Pulse-Echo Ultrasound |
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