Ultrasonic Inspection of Carbon Fiber Composite Layers
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Solution Overview
Problem
Existing ultrasonic inspection methods cannot accurately determine if all necessary layers are present in composite parts made from carbon fiber reinforced plastics, as they may fail to detect missing or excess layers within the tolerances of the component.
Innovation Solution
A method and device for ultrasonic inspection that involves determining the runtime and/or attenuation of an ultrasonic signal through a composite part and subtracting the corresponding data from a reference composite part to detect missing or additional layers, while also identifying other quality deviations such as delamination, porosity, or foreign object debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic inspection methods are used, then the inspection process is simple and quick, but the method cannot accurately detect missing or additional layers within tolerance ranges
Solution Approach 1:
The inspection method segments the ultrasonic signal analysis into multiple independent evaluations: runtime analysis, attenuation analysis, and reference comparison analysis. Each segmentation focuses on specific layer characteristics, enabling precise detection of missing or additional layers while maintaining systematic complexity management
Solution Approach 2:
The method changes multiple ultrasonic signal parameters simultaneously - both runtime and attenuation characteristics are measured and compared against reference values. This multi-parameter approach enables accurate layer detection by identifying deviations in either parameter that indicate missing or additional layers
2Reliability
If conventional ultrasonic testing is applied, then the testing process is fast, but it cannot determine whether all necessary layers are present in the composite part
Solution Approach 1:
A reference composite part is inspected beforehand to establish baseline runtime and attenuation values for the correct number of layers. This preliminary action creates a reference dataset that enables rapid comparison with test parts, ensuring reliable layer completeness determination without time-consuming manual counting during actual inspection
Solution Approach 2:
The method creates a copy of the expected layer structure through reference measurement, storing the ultrasonic signal characteristics of a known-good composite part. This copied reference data is then compared against test samples to quickly identify deviations indicating missing or additional layers, maintaining fast inspection speeds
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for non-destructive testing to accurately detect missing or additional layers and other quality issues in composite parts, enhancing the reliability of composite part inspections and ensuring compliance with design specifications.
Implementation Method 1
determining the runtime and/or attenuation of an ultrasonic signal propagating through the composite part to be inspected
Data Source
AI summary
A method for ultrasonic inspection of composite parts includes providing a composite part to be inspected with a plurality of layers, determining the runtime and/or attenuation of an ultrasonic signal propagating through the composite part to be inspected, providing the runtime and/or attenuation of the ultrasonic signal propagating through a reference composite part, subtracting the runtime and/or attenuation of the ultrasonic signal in the reference composite part from the runtime and/or attenuation of the ultrasonic signal in the composite part to be inspected, or vice versa, and determining from the result of the subtraction one or more missing and/or additional layers in the inspected composite part. The difference of the runtime and/or attenuation of the ultrasonic signal in the inspected composite part relative to the reference composite part, and/or the difference of the thickness between the composite part and the reference part, is/are visualized.