Automated non-destructive evaluation of composites and additive manufacturing

Aeroplane wing and fuselage panels, with a span of several meters long, are subjected to cyclic loads during take-off, landing, and taxiing. These components which are majorly manufactured from Carbon Fiber Reinforces Polymer (CFRP) composites are subjected to fatigue cracking and impact damages causing matrix cracking, ply delamination, fiber rapture, and indentations due to the loading conditions during the service or manufacturing faults.

Accordingly, the components should be inspected I) at the point of manufacturing for any fabrication flaws to be rectified before entering the service, and II) periodically during the service using Non-Destructive Testing (NDT) methods to ensure their safe operation during their expected service life. Traditionally, an inspector with handheld Eddy currents/ultrasonic testing probes scans the surface of such components inch by inch for potential defects that may have been developed during the service. The inspection by the manual Eddy currents/ultrasound scanning method is a very time-consuming process, which can sometimes last for days. Furthermore, the inspection results could be adversely impacted by the tiredness of the inspector, time of the day, and the working environment. To alleviate these problems which could introduce variation in the test results or even lead to missing defect indications, which could have disastrous consequences, newer automated inspection methods are desired by the aerospace companies and airlines.

The project initially targets the assessment of the efficiency of different electromagnetic NDT methods alongside ultrasonic testing for inspection of composite materials, and then, it aims at automation of the Eddy currents/ultrasound inspection process with the help of industrial robots. To this end, firstly, the inspection path should be programmed for the robot controller, so the robot manipulates the eddy currents/ultrasound sensor on a flat surface along the desired inspection path. Secondly, the robot should be interfaced with the Eddy currents/ultrasound controller to communicate effectively during the acquisition process, and this is to ensure that the inspection data collected is tagged with the correct positional data from the robot controller. This is essential for locating the defects when the inspection results are reviewed.

The students during this multidisciplinary project will simulate, design, and build electromagnetic/ultrasonic sensors, integrate them in automated system, and evaluate the performance of each inspection system for aeroplane composite wing panels