Non-Destructive Testing in the aerospace domain NDT - CCT

Transcription

© NDT expert - The ultimate control
2007
Non-Destructive Testing in the aerospace domain
NDT Expert experience
Fernando SANTOS - NDT Expert, France
Journée CND, CNES
Contents
¾ 1. Summary
¾ 2. NDT Expert, presentation
¾ 3. The EngineeringAT division
¾ 4. NDT Expert experience on the space sector
4.1 NDI on production/integration sites
4.2 NDI for feasibilitiy studies
4.3 NDI support for expertises
¾ 5. Conclusions
2007
Journée CND, CNES
1 - Summary
¾NDT Expert
Presentation of NDT Expert services and main objectives
¾EngineeringAT
The role of the Engineering department for internal and external clients
¾NDI support to production / integration sites
NDT Expert activities for production and integration facilities for “daily” work
¾NDI support to feasibility studies
NDT Expert activities to support the feasability studies Æ Procedure writing, choice of materials...
¾NDI support for expertises
NDT Expert activities on unexpected events, follow-up of suppliers, specific inspections...
¾Conclusions
Feedback on 16 years of activity
2007
Journée CND, CNES
2 – NDT Expert
2007
Journée CND, CNES
3 - EngineeringAT
AT
Engineering
: preparing the future
AAT
T
Technology transferts
En
gi
ne
er
in
g
High level expertises
Research & Development
Advanced technologies
Innovative Techniques assessment
Development
industrialisation
Î Customized
solutions
2007
Journée CND, CNES
3 - EngineeringAT
•Fast and reliable inspection tools
• Ultrasound arrays
• Eddy current arrays (for corrosion and subsurface fatigue cracks)
• Digital X-ray (pulsed sources)
• Shearography for impact damage assessment (CFRP/sandwich structures)
• Infrared imaging by microwave excitation (CFRP/sandwich structures)
•Fast Assessment and Reporting
• Moireview (dents and rivet pull-in)
• Shapeview (shape measurement)
• Scratchview (in progress)
• Wireless scanning (in progress)
•Development of structural health monitoring systems
• Crack monitoring (eddy current foil sensors),
• Water ingress (microwave antennas),
• Impact (shock detector)
2007
Journée CND, CNES
3 - EngineeringAT
Fast and reliable inspection tools
UT Phased array
Real time Bscan imaging and Cscan imaging.
Delaminations in composites.
Large volumes inspected without moving the probe.
Easier detection and sizing of damages.
Crack detection at bore hole.
Porosity and cracks in
metallic parts.
2007
Journée CND, CNES
3 - EngineeringAT
Eddy current array
2007
Feasibility and procedure
development for corrosion mapping
and subsurface crack detection
First deployment at Astrium ST,
Aquitaine and Mureaux
Journée CND, CNES
3 - EngineeringAT
Use of modeling tools (CIVA)
) Calculation of ultrasonic fields.
) Modelling of ultrasonic inspections.
) Modelling of Eddy current inspections.
To predict and assess:
• Probe choice and /or design.
• Limits of use.
• Inspect ability.
• Definition of inspection conditions.
Array lobes
2007
Journée CND, CNES
3 - EngineeringAT
Digital X-ray system for in-service applications
9.5mm lap joint with electro-eroded and fatigue cracks: zoomed image - fatigue crack of 0.1mm width
2007
Journée CND, CNES
3 - EngineeringAT
Digital X-ray system for in-service applications
Exposition parameters
(Exposure time and gain)
Scanning area parameters
(X, Y displacement)
Software interface for X-ray detector displacement
2007
Journée CND, CNES
3 - EngineeringAT
Shearography – Fast damage assessment
2007
Deployment:
For what?
• Elevons
- CFRP/Nomex
• Ailerons
(disbonding, delamination and honeycomb cracking)
• Wing tips
- CFRP/foam
• Winglets
(disbonding, delamination and foam cracking)
Other results on representative samples:
• Rudder, Radome …
Journée CND, CNES
3 - EngineeringAT
WISKit - Water Ingress Stimulation Kit
¾ Multi-frequency sequential excitation Æ more even EM fields
¾ 40 W output power
Buzzer
Off
Off
RF OUT
Stand by
2007
Test led
Measure Measuring led
Journée CND, CNES
3 - EngineeringAT
WISKit - Water Ingress Stimulation Kit
Inspection performed with set-up on
horizontal stabilizer (TBC)
External view
WISKIt with 2
connexions
“Antennas”
With conventional thermal excitation
With microwave thermal excitation
ELEVATOR
2007
Journée CND, CNES
3 - EngineeringAT
Fast Assessment and Reporting
Moireview - Dent and rivet pull-in characterization
Deployed @ Airbus (Filton, St. Nazaire, Toulouse), EADS ST, EC-D, Latecoere, Embraer
2007
Journée CND, CNES
3 - EngineeringAT
Shapeview – Automatic shape inspection system
Specifications
•
•
•
•
•
•
•
•
•
2007
Size of the inspection area : 1 m X 0.75 m
Accuracy : 50 µm
Spatial resolution : 5 mm
Working Distance : 1m
Measurement Time : 1/1000 s
Calculation Time :< 1 mn
Portable and autonomous; power supply :
batteries
No need for any holder or tripod : the
measurement is made by the operator
supporting the system by hands
Possibility to achieve measurements on bright
surfaces with a reasonable sunlight (50 KLux)
Tool for the A380 Enhanced Support - SDRM
Journée CND, CNES
3 - EngineeringAT
ScratchView - Scratch characterization tool
Technical data:
• Weight : < 1.5 kg
• Dimensions : < 150 X 150 X 150 mm3
• Accuracy in depth : 5 µm
• Spatial resolution : 2 µm
laser line projection
Laser Diode
Camera
• Autonomous (battery powered)
• Fully portable
•Easy to use by non experimented
operators.
Specimen
Scratch
2007
Journée CND, CNES
3 - EngineeringAT
Wireless scanning system (concept Æprototype)
Générateur
US ou CF
Signal US ou CF
PC
E/R
Valeurs des compteurs
POSUS
Impulsion
de synchro
Récepteurs ultrasons
US air
• Fast reporting
• Traceability
US air
Câbles de connexion.
émetteur
PVDF
Sonde US
ou CF
• Archiving for minor damages
2007
Journée CND, CNES
3 - EngineeringAT
Development of structural health monitoring systems
A – Identification of scenarios for maintenance and
cost benefit assessment
• NTM, MPD and AMM analysis
B – Development of sensors
• Eddy current foil sensors
• Microwave antennas
• Shock detector
C - Implementation of sensors
• Technical note
• Physical implementation
• Follow-up
2007
Journée CND, CNES
3 - EngineeringAT
Cost assessment on 4 maintenance scenarios
1 – Replacement of conventional NDT inspection - (decreasing aircraft DMC)
2 – Replacement of conventional NDT inspection – (decreasing aircraft DMC)
3 – Monitoring of aircraft sensitive part (increase aircraft safety)
4 – Follow-up of aircraft critical zone (increase airline aircraft availability)
A300 NTM 53-30-52
2007
A320 NTM 55-20-06
A300 SB 53 0246
No compulsory inspection
on landing gear doors
Journée CND, CNES
3 - EngineeringAT
Eddy current foil sensor for
crack detection and monitoring
Microwave antennas for water
measurement and location
inside sandwich structures
Shock detector for impact
characterization on composite
structures
2007
Journée CND, CNES
4. NDT Expert experience on the space sector
4.1 NDI on production/integration sites
4.2 NDI on feasibilitiy studies
4.3 NDI support for expertises
2007
Journée CND, CNES
4 – NDT Expert experience on the space sector
4.1 Support to production/integration sites
To be able to support industrials during ramp up periods or pre defined overload
To be able to support industrials with short NDI capabilities
To be able to support industrials on specific NDI requests
Most of the recurrent work deals with X-ray and UT
- Assessment of assembling process (RT and UT)
- Assessment of disbonding on sandwich structures (ST and Resonance)
- Assessment of dimensional values after manufacturing/assembling process (RT)
- Assessment of structural damage after manufacturing process (UT)
2007
Journée CND, CNES
2007
X-ray control of cables
integrity after assembly
Journée CND, CNES
45,7°C
Thermographic control of
bonded heaters
44
42
40
38
36,8°C
30,4°C
30
29
35,1°C
35
34
28
33
27
26
25
32
31
24
30
23
22,4°C
2007
29,3°C
Journée CND, CNES
2007
X-ray control of cables
integrity for thermistance
integrity assessment
Journée CND, CNES
2007
X-ray control of pyrotechnique
separation nut for dimensional and
assembling quality assessment
Journée CND, CNES
2007
Thermographic control of different
waveguide components after
assembling
Journée CND, CNES
4.2 Support to feasibility studies
To be able to choose the best method for a specific application
To be able to provide clear information by defining inspection procedures
Work on:
- New materials and geometries (ceramics, polimers …
- New assembling processes (welding , bonding…
- Faster inspections
-…
2007
Journée CND, CNES
Optimisation of X-ray inspection of
satellite pipes
Inspection radioscopique numérique
d’assemblage par brasure
Faster and more
reliable inspections
2007
Journée CND, CNES
2007
Inspection procedure for new
assembling method
Journée CND, CNES
Development of inspection procedure
for faster and more reliable control
0.97
0.74
0.51
0.28
61.2
0.04
38.0
-0.19
14.1
-0.42
-0.65
-0.88
-1.12
3.1
21.8
41.2
60.0
79.6
98.4
117.8 136.5 156.2 174.9 194.3
mation [µm\shear]
2007
Journée CND, CNES
Ceramic SiC integrity control with:
2007
- Dye penetrant
- Ultrasound
ep=3 mm
- X-ray
α
α
Journée CND, CNES
Infrared imaging and shearography
study on CFRP assemblies
Renfort carbone EP=2.4
Lampe halogène
Colle Redux 312 L
Renfort carbone EP=0.3
Colle Redux 312 L
Semelle carbone EP=0.3
Colle Redux 312 UUL
Tête shearographique
(Système optique + laser)
NIDA 6-20
Faisceau Laser
NIDA 3-20
Décollement
Objet
Traitement d’images
2007
Journée CND, CNES
2007
X-ray and UT investigation on AL-Ti
diffusion assembly structures
Journée CND, CNES
UT investigation on Steel/Cobalt
welding integrity
« Detection of lack of fusion »
Conclusions and recommendations:
« La méthode utilisée devrait permettre de détecter des manques de fusion à
l’interface tôle-métal d’apport. Une validation complète de la soudure
nécessitera la réalisation de trous à fond plat situés à l’interface acier-métal
d’apport et d’un diamètre équivalent au plus petit défaut à détecter.
Remarque : avec les réglages utilisés, le trou à fond plat de diamètre 1.2mm
situé à une profondeur de 30mm (bloc aluminium) est détecté. »
2007
Journée CND, CNES
Axe
sonde
Inspection investigation
on C-C tubes by UTPA
Sonde
ultrasonore
Relais
plexiglass
Sens propagation
uultrason
R 47
Disbonding
Tube
carbone
bobiné
Sound area
Equipement : - OMNISCAN MX – Version 1.0B3
Probe : 5MHZ – 64 éléments – Relais SI1N0L.
Reflection mode
Defects to detect: Disbondings between Al skin and Al honeycomb
2007
Journée CND, CNES
4.3 Support to expertises
To be able to make a critical statement on the most diverse structural configurations
Work on:
- Follow-up of suppliers NDI capabilities
- Expertises after unexpected events (impacts…)
- Expertises following reworking/repairs
- Expertises after malfunctioning
-…
2007
Journée CND, CNES
Zone droite de la « pressure vessel » :
Défaut d’usinage ou d’ajustement pouvant entraîner une
soudure non acceptable
Follow-up of subcontractor:
- Audit, due to poor NDI assessment by OEM
- Recommendations to improve NDI methods
- Analyze of improvements
2007
Journée CND, CNES
CFRP ultrasound inspection
for delamination around
skin drilling
Inspection of area surrounding hole
Inspection with hole protected by watertightness insert
Geometrical constraints
-
Probe dimension (diamètre 7.5mm)
-
Active probe diameter (diamètre 3mm)
Area close to the hole (~2mm to 2,5 mm) it cannot be inspected
2007
Precise and well
defined inspection
constraints for clear
damage
assessment
Journée CND, CNES
Foils integrity
X-ray inspection of a Li-Ion
battery module
Bypass
Inspected
cells
film
1
3
2
4
6
X-ray source
5
2007
Journée CND, CNES
Eddy current inspection by pencil and
rotating probes after reworking
Area inspected by rotating probe
Front flange Dewar fixation
2007
Inspected areas by pencil probe
For crack detection open to the surface.
Journée CND, CNES
X-ray inspection of tube after
laser welding failure
Investigation allowed to:
- Detect failures at tube weldings
- Probable causes are:
- Lack of penetration
- Floating welding width
- Unsatisfying
between
tube
structure
2007
adjustment
and
base
Journée CND, CNES
Other expertises:
- X-ray inspection on electrical cable to detect thickness reduction
- Shearography inspection on antenna after impact
- Ultrasound inspection on CFRP tube after impact
- Shearography inspection on bonded brackets after machining
- Ultrasound inspection on metallic frames
2007
Journée CND, CNES
5 – Conclusions
Major difficulties:
Most of the times industrials only have general procedures
Work with no procedure
Work without calibration standard
Different configurations of satellites
Major NDT Expert assets:
- Deep knowledge of all NDI methods and techniques
- Work force with several Level 3 techniciens and PhD (experimental mechanics, material
science, optics, ultrasounds, thermography)
- Flexibility and reactivity
- Different equipments adapted to expertises
full field techniques, allow to work without calibration standard
comparison between sound and damaged area (Shearography,
thermography, X-rays)
- R&D activity through national, european and EADS research programs
2007
Journée CND, CNES

Non-Destructive Testing in the aerospace domain NDT - CCT

Transcription

Similar documents

- Malaysian Society for Nondestructive Testing

MINDTCE 09, 20th-21st July 2009

stall this

Ammonia System Inspection Services

services in ndt - Amotus Solutions

NOVELTIES CRAWLERS.From Baltospot

Excellence in advanced quality system

Frei Caneca St. 569 - São Paulo - Brazil August 22 to 25