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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Veröffentlicht in:Materials 2021-05, Vol.14 (11), p.2919
Hauptverfasser: Blackman, Nathaniel J., Jack, David A., Blandford, Benjamin M.
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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. 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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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