X-Ray Tomography Characterization for Woven Composite Materials
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Solution Overview
Problem
Current methods for characterizing composite materials with woven, braided, or sewn fiber reinforcement are destructive, limited to small volumes, expensive, and struggle to accurately measure parameters like contraction and waviness, especially in large volumes, leading to incomplete and error-prone results.
Innovation Solution
The method employs X-ray tomography to determine gray levels within the composite material, distinguishing between the fiber threads and matrix, allowing for non-destructive characterization and accurate measurement of parameters such as thread volume fraction, warp/weft ratio, and contraction angle through deconvolution of Gaussian curves and Fourier transforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If chemical dissolution and weight measurements are used to determine fiber fraction, then fiber fraction can be obtained, but the method is destructive and limited to small volumes only
Solution Approach 1:
The patent replaces chemical dissolution methods with X-ray tomography imaging. Instead of chemically etching and weighing small samples, the invention uses non-destructive X-ray imaging to visualize and measure fiber reinforcement characteristics throughout the entire part volume, eliminating the need for destructive sampling while maintaining measurement capability
Solution Approach 2:
The patent transitions from 2D section plane measurements to 3D volumetric characterization using X-ray tomography. By imaging the entire volume and reconstructing 3D data, the method overcomes the limitation of small sample volumes and provides comprehensive characterization of fiber fraction, spacing, and distribution throughout the whole part
2Measurement precision
If section planes are made to measure distances between columns, then some information can be obtained, but it is difficult to ensure the section follows all threads and measure contraction and waviness accurately
Solution Approach 1:
The patent uses 3D X-ray tomography to reconstruct the entire volume of the part, allowing measurement of fiber reinforcement characteristics in three dimensions. This eliminates the problem of 2D section planes missing threads or failing to capture contraction and waviness, as all features are visible and measurable throughout the full 3D volume
Solution Approach 2:
The X-ray tomography method provides universal measurement capability for all fiber reinforcement parameters (fiber fraction, spacing, contraction, waviness, warp/weft ratio) within a single imaging process, rather than requiring multiple separate measurement techniques that each have limitations
3Measurement precision
If traditional characterization techniques are used, then some parameters can be obtained, but the methods are expensive in terms of time required and give rise to waste that is difficult to recycle
Solution Approach 1:
The patent replaces time-consuming chemical dissolution and manual measurement processes with automated X-ray tomography imaging and digital image analysis. The entire characterization process is performed non-destructively in a single imaging session, significantly reducing the time required while maintaining or improving measurement accuracy
Solution Approach 2:
The patent creates a digital 3D copy of the internal structure through X-ray tomography imaging. This virtual model allows for repeated measurement and analysis of all fiber reinforcement parameters without physically touching or consuming the actual material, eliminating waste and enabling rapid re-analysis
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 enables precise, non-destructive characterization of large composite material samples, providing previously difficult-to-access information quickly and efficiently, suitable for complex aviation parts like aeroengine components without the drawbacks of traditional methods.
Implementation Method 1
using X-ray tomography to determine gray levels of at least a portion of the article
Implementation Method 2
determination step of using X-ray tomography to determine gray levels of at least a portion of the article
Data Source
AI summary
A characterization method for characterizing an article made of composite material having woven, braided, or sewn fiber reinforcement, the method including a determination step of using X-ray tomography to determine gray levels of at least a portion of the article, followed by an exploitation step of exploiting the gray levels to obtain information concerning the weaving by distinguishing between at least the free matrix and the threads of fibers mixed with the matrix, the threads being considered as being a material that is homogeneous.