Ultrasonic NDT for Composite Ply Characterization
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Solution Overview
Problem
Current non-destructive testing (NDT) techniques are inadequate for accurately identifying and characterizing composite laminate structures, particularly in determining the properties of individual plies and generating a failure envelope without destructive testing, which is essential for assessing structural integrity and manufacturing uncertainties.
Innovation Solution
A system and method using ultrasonic non-destructive testing (NDT) techniques to characterize composite laminates by determining ply properties such as number, orientation, and type, and calculating failure loads, generating a probabilistic failure envelope based on scan data from ultrasonic scans or simulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current non-destructive testing techniques are used, then structural integrity assessment is possible, but accurate identification and characterization of composite laminate structures and individual ply properties cannot be achieved
Solution Approach 1:
The system segments the composite laminate into individual plies and characterizes each ply separately by determining properties such as fiber orientation, thickness, and material composition for each layer. This segmentation enables accurate identification of individual ply properties while maintaining reliable structural integrity assessment through cumulative analysis of all plies.
Solution Approach 2:
The system employs multiple ultrasonic frequencies and measurement parameters to characterize different aspects of the composite structure. By varying frequency parameters and analyzing multiple signal characteristics, the system achieves precise ply property identification while ensuring comprehensive structural assessment.
2Measurement precision
If destructive testing is used to determine failure envelope, then accurate failure data is obtained, but the structure is damaged and cannot be used
Solution Approach 1:
The system creates a virtual model (copy) of the composite laminate by non-destructively measuring and characterizing each ply's properties. This digital twin includes fiber orientation, thickness, and material properties, which are then used in computational analysis to predict failure envelopes, eliminating the need for physical destructive testing.
Solution Approach 2:
The system replaces physical mechanical testing with computational mechanics. Instead of applying physical loads to determine failure points, the system uses ultrasonic measurements combined with computational models to predict failure envelopes, preserving structural integrity while achieving accurate failure data.
3Loss of information
If original manufacturing data is available, then accurate laminate characterization is possible, but such data is often unavailable for aging structures
Solution Approach 1:
The system enables aging structures to self-characterize by using ultrasonic measurements to automatically determine ply properties such as fiber orientation, thickness, and material composition without requiring original manufacturing records. The structure essentially measures and reports its own current state.
Solution Approach 2:
The system performs preliminary non-destructive measurements to capture current ply properties before any degradation occurs. By measuring and storing the actual in-service condition of each ply, the system creates an accurate baseline for future monitoring and analysis, eliminating dependence on potentially unavailable or outdated manufacturing data.
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
Enables non-destructive assessment and quality assurance of composite laminate structures, reducing manufacturing and maintenance costs by providing detailed structural information and failure envelopes without requiring original manufacturing data, thus supporting the maintenance of aging structures and ensuring compliance with design specifications.
Implementation Method 1
signal reflected and refracted off material transitions within the composite laminate
Implementation Method 2
ultrasonic non-destructive testing (NDT) techniques
Implementation Method 3
signal intensity and signal time-of-flight for a signal reflected and refracted off material transitions
Data Source
AI summary
Embodiments are disclosed for characterizing and quantifying composite laminate structures. The embodiments take a composite laminate of unknown ply stack composition and sequence and determine various information about the individual plies, such as ply stack, orientation, microstructure, and type. The embodiments distinguish between weave types that exhibit similar planar stiffness behaviors, but produce different failure mechanisms. Individual ply information is then used to derive the laminate bulk properties from externally provided constitutive properties of the fiber and matrix, including extensional stiffness, bending-extension coupling stiffness, bending stiffness, and the like. The laminate bulk properties are then used to generate a probabilistic failure envelope for the composite laminate. In some embodiments, ply stack type and sequence are also determined for a curved composite laminate using the disclosed embodiments by adding a rotational stage.