NDT FOR COMPOSITE

MATERIALS

SUMMARY
1. Normative

2. Main techniques used on FRP Components

3. Specification for NDT Methods in FRP component
4. Potential Trans-IND techniques for inspection of
composite component for civil applications
5. Beam inspection by Ultrasound system
6. Deck inspection by Thermography system
2

Normative
Very different techniques
Non destructive testing

Very different
application

Always in evolution

ASTM Standard

It is important to have a
normative to apply these
techniques correctly
3

ASTM E 543-04
ASTM 543-04 norm report the list of all NDT norms
There are the lines guide to evaluate testing and safety agencies

There are a short description of the equipment for each

nondestructive testing.
There is an important table with the comparison of NDT
methods

Comparison of NDT methods in ASTM E 543-04

Comparison of NDT methods in ASTM E 543-04

E07 on Nondestructive Testing

REAPPROVAL OF
STANDARD
Volume 03.03
E 431-96(2007)
E 650-97(2007)
E 1495-02(2007)
E 1774-96(2007)
E 1814-96(2007

REVISION OF STANDARD
Volume 03.03
E 569-07 Practice for Acoustic Emission Monitoring
of Structures During Controlled Stimulation
E 1106-07 (Includes change to title) Test Method for
Primary Calibration of Acoustic Emission Sensors
E 1211-07 Practice for Leak Detection and Location
Using Surface-Mounted Acoustic Emission Sensors
E 1816-07 (Includes change to title) Practice for
Ultrasonic Testing Using Electromagnetic Acoustic
Transducer (EMAT) Techniques
E 1888/E 1888M-07 (Includes change to title) Practice
for Acoustic Emission Examination of Pressurized
Containers Made of Fiberglass Reinforced Plastic with
Balsa Wood Cores
E 1932-07 Guide for Acoustic Emission Examination
of Small Parts
E 2192-07 Guide for Planar Flaw Height Sizing by
Ultrasonics

Main techniques used on FRP Components

Ultrasonic Testing (contact and non contact)
Ultrasonic testing is used to detect
delaminations, porosities, cracks or inclusions.
It is also possible to determine the thickness,
fibre distribution, fibre alignment, and the
curing state. The ultrasonic probe emits
ultrasonic waves into the material. These waves
are reflected by the face opposite to the probe.
The probe collects these signals and they are
visualised on a screen. So the thickness can be
determined of the sonic velocity of the material
is known. If there is a defect, an inclusion or a
fibre in the material the waves are reflected by
this object and it is visible on the screen.

The system can work, in the

form of A scan or C scan.

Emitter

Signal
conditioning

SIGNAL MEASUREMENT

Receiver

Frequency range: from 20 kHz to 25 MHz

The A scan display is similar to an oscilloscope display, giving

the time of flight and reflection amplitude data.
The C scan requires additional scanning equipment and
displays a plan view of the detected

Main techniques used on FRP Components

Thermography
Thermography is used to detect
delaminations, bonding defects, and
inclusions or to determine the fibre
concentration. Therefore the surface
of the part is heated. Inclusions or
defects alter the flow of the heat.
With an infrared camera the
temperature distribution is recorded.
With thermography only defects that
are close to the surface can be
detected.

Infrared lamp

defect

heating

No-defect area

object

Time of inspection

Passive thermography : The features of interest are naturally at a higher

or lower temperature than the background
An energy source is required to produce a
Active thermography : thermal contrast between the feature of
interest and the background

Main techniques used on FRP Components

Radiography
Radiography uses a penetrating radiation source such as X-rays or gamma rays and
radiographic film to capture images of defects. Differential absorption of the penetrating
radiation by the specimen will produce clearly discernible differences when recorded on
radiographic film. Radiography requires access to both sides of the structure
With radiology not only voids, contaminants or trans laminar cracks can be detected but also
the fibre orientation can be reviewed.
An alternative to traditional radiography is
the real time radioscopy where the
penetrating radiation produce an image on
a video monitor The X-ray image is
obviously limited to the image intensifier
screen diameter.
The quality image as sharpness, contrast
and noise depending on converts the
analog signal of the sensor in to a digital
data stream.
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Main techniques used on FRP Components

Visual inspection by image analysis
We consider the evolution of the technique for the automation,
like a technology of artificial systems that extract information
from images. This technology can be applied on controlling
processes, superficial defects, detecting events, modeling
objects or environments etc.. An optical access is necessary to
apply this technique. Its performance depends on the optical
sensor, illumination and processing system. The inspection can
be made in real time during the production with immediately
information on the anomalies.

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Main techniques used on FRP Components

Shearography
Shearography is an optical interferometric technique that measures the first derivative of
the out of plane displacement of a deformed object. A shearography system is, in fact,
generally composed of a Michelson interferometer with simple changes that allows shear
application.
It belongs to the speckle measurements. A speckle visualises a raw surface as granules-like
intensity distribution. The resulting intensity distribution is compared to the distribution of
a loaded part. Its ability to measure large areas in one shot without contact.

12

Main techniques used on FRP Components

Acoustic emission testing
In acoustic emission testing, an elastic wave
is generated by the rapid release of energy
from within a material. A structure under
certain load levels produces acoustic sound,
usually in the range between 20 kHz and 1
MHz. This sound generation is known as
acoustic emission. Acoustic Emission is
simply the stress waves generated in the
materials due to deformation, crack
initiation and growth, crack opening and
closure, fiber breakage, and delamination in
composite materials. The elastic waves come
through the solid to the surface where they
can be recorded by one or more
sensors/transducers. Acoustic Emission
listens for emissions from active defects and
is very sensitive to defect activity when a
structure is loaded.
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Specification for NDT Methods in FRP component

Specification for NDT Methods in FRP component (2010)
Defect Size

Acoustic Emission

Radiography and
Radioscopy

Thickness inspection

Inspection Time

Potential
Cost

Difficulty Use

No restrictions

Depending on the
sensor number and
location

Low,
but the cost
depends on
number of
sensors

Technical expert,
easy test,
structure must
be loaded; no
feasible off-site

Up to 40 cm/s

> 30.000

Technical expert,
high danger

70.000
-100.00

Technical expert,
high

15.00020.000

Technical expert,
medium

Defects with
different
dimensions but
must be able to
generate acoustic
emissions

> body
granulometry

Peack
Voltage
(kVp)

Half Value Layer (mm)

Lead

Concrete

50

0.06

432

100

0.27

15.1

150

0.3

22.32

Shearography

Thermography

Down to
10-20 mm

Around 5-7 mm

Real-time
measurement
up to 120s depending
on load gradient and
depth; typical
inspection area
200x300 mm2

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Specification for NDT Methods in FRP component

Specification for NDT Methods in FRP component (2010)
Defect Size

Contact

Down to
1-2 mm

No
contact

Down to
10-20 mm

Ultrasound

Visual inspection

Depending on
resolution of
sensor and
inspection area

Thickness inspection

Depending on material, structural

components, probe frequency (e.g.
up to 150-200 mm in FRP monolithic
element)

Superficial defect

Inspection Time

Potential Cost

Difficulty
Use

Area of 100x100mm2
down to 1.5 min

15.000- 20.000
without robot
scanner,
immersion
system etc.

Technical
expert,
medium

Area of 100x100mm2
down to 3 min

20.000-40.000

Technical
expert,
medium

Real time

Variable,
depending on
sensor
resolution and
illumination

Technical
expert,
medium

In the inspection time the post processing time has not been considered.
The data of the Table are just indicative, the performance and the cost can change for each specific case,
depending on optimization level of the technique, technology evolution and inspection level.
The potential costs in Table are only for the equipment of measure without the automation cost.
The automation cost can be variable depending on the technique choice and of the automation level.

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Potential techniques for inspection of composite

components for civil applications
The choice of the best technique, for each specific application, requires
knowhow and a dedicated analysis of the specific case.
Operative conditions

Requirements

on-site
off-site
on-line
off-line
Component to inspect: Bridge Components,
Composite material, Large area.
Time of inspection
Resolution of inspection
Depth of inspection

Limits of technique

Area of inspection
Portability

Cost/benefit ratio

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Choice of the best NDT for Trans-IND

Analysis of the components to inspect
Objective:
Detect internal defects for Bridge Elements,
in particular samples of the Beam and Deck,
in composite material, on-site, for large
areas

Characteristics of components:

66 mm

50 mm

High thickness (up to 66 mm)

Complex shapes
Sandwich structures (with lower core
density, 40 kg/m3)

Beam sample

Deck sample
These
characteristics
limit
the
application of most common non
destructive techniques
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Choice of the best NDT for Trans-IND

Requirements for the components to inspect
large area of inspection
Techniques
Thickness:
Skin 8 mm
Core 50 mm

Thermography

high thickness of inspection

fast

Thickness of GFRP
profile: 3-6 mm

sandwich element inspection

Full field technique

Large area of inspection in one frame
Easy to use
Cost contained
It has the limit of thermal penetration
(inspection depth: till 7-8 mm on CFRP)
Emissivity variation and external
reflections affect the temperature pattern
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Choice of the best NDT for Trans-IND

Requirements for the components to inspect

Shaerography

Ultrasonics

Full field technique

Large area of inspection in one frame
More sensitive to mechanic vibrations

The ultrasonic is the best technique

to inspect high thickness and
different materials
It can be applied adopting many
configurations.
The use is limited in the case of
complex shapes
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Potential Technique Ultrasonic inspection

Ultrasonic phase array
Advantages

Disadvantages
Commercialized transducers have
frequencies higher than 500 kHz
Lower frequency probes require larger
size of each element -->

Inspection of large areas

Curved shapes
Fast inspection

- Decrease of resolution
- Difficulty to realize complex shape
- Difficulty to move on raw surface

Air-coupled ultrasonic

non-contact
no problem with raw surface
no problem with curved shape
easiness of movement

large gap of acoustic impedance

between the FRP and air
attenuation more than 150 dB on
CFRP components
No energy passes through a
sandwich with a foam core
20

Ultrasonic inspection
Water-coupled
Advantages

Disadvantages

different degrees of freedom are

possible
no problem with raw surface
potentially applicable on
complex shapes
potentially applicable to inspect
high thickness

complex system for big

components:
big basin required
Anthropomorphic robot to
move on complex shapes
difficult of apply off-site

Classical contact ultrasonic

potentially the best technique (pulse echo
and trough transmission mode) to inspect
high thickness elements.
High energy pass through the element

difficult to scan of raw surface

difficult of inspection on shapes
with strong curvature.
inspection of high thickness
components --> low frequency -->
low resolution of the defect
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Potential solutions for bridge elements with flexible installation and large
area inspection

Laminate panels,
monolithic elements

Thermography for samples up to 7-8

mm in depth
Air-coupled ultrasonic transmission
mode up to 1-3 cm
Contact ultrasonic transmission
mode over 3 cm
Ultrasonic with low frequency probes
(100 kHz) need.

Sandwich with
PUR Core

66 mm

50 mm

Air-coupled ultrasonic up to 15 mm in
depth.
Contact ultrasonic probes in
transmission mode are necessary for
depth up to 15 mm.

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1 Case study - Sandwich sample

Characteristics/limits for inspection:
Sandwich structures
2 skins in FRP (mix of Glass and Carbon Fibers)
1 low density PUR core (40 kg/m3)
High thickness
Skin of about 8 mm
Core of about 50 mm
66 mm

50 mm

Complex shape
Curvilinear profile
Rough surface
Variable thickness

Rough surface

Technique of inspection: Contact Ultrasonic

Problems
To move the contact probe on rough surface.
To maintain the right coupling on bottom surface
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The proposed inspection method

Hybrid configuration
Contact
emitter probe

Non-contact
receiver
probe

The emitter
contact probe

It generates a high energy

ultrasound
wave
that
travels through the element
to be inspected
Low frequencies 100 kHz
probe
allows
lower
attenuation
in
high
thickness components

The non-contact
receiver probe

It allows to have more

freedom to follow the profile
It solves the problems of
contact with bottom surface
(coupled with water, oil,
hanging)
It solves the problem to
move on rough surfaces

Equipment
The Ultran Group
pulser and receiver:

Digitizer NI PCI 5122

acquisition board:

emitted signal: Burst;

Max excitation voltage: 475 V pk-pk;

14-bit resolution;
100 MS/s real-time;

24

Further improvement solution

Further improvements, to overcome limits due to high curvature, rough surface and low
spatial resolution, have been done.
In experimental stage a thin spherical cap (1 mm) on the low frequency contact probe (100
kHz) has been applied.
Contact emitter
probe with
spherical cap

Water

Spherical
cap

The thin thickness and the cap filled with water reduce interferences on the wave
transmitted
The use of spherical element has also the objective of focusing and amplifying the beam
To support the sphere design and optimization a numerical simulation has already started
25

Simulated defects
50 cm

74 cm

Defects

x
Core defect 10x3x30 mm

Skin defect 10x2.5x30 mm

Defects

The probes can be moved on the area of inspection by a Cartesian robot for planar shapes or
by an anthropomorphic robot for complex shapes
In this work a Cartesian robot has been used
Area inspected: 50x74 mm
Spatial resolution: 1 mm
Scan speed: 100 mm/s

26

Detection sandwich component

Hybrid configuration
Core defect 10x3x30 mm; skin defect 10x2.5x30 mm

without spherical cap

SNR 19 dB

with spherical cap

SNR 13 dB

Core defective
area
Defects

edge effect

Skin Defective
area

x
artefact

In both cases the skin defect and core defect have been detected
In the map with spherical cap, the edge effects and artefacts are reduced
The signal to noise ration (SNR) is lower with spherical cap (13 dB) but still good enough to
27
detect defects

Improvement of the flexibility

Spherical cap - FEM simulation

Upgrade the spherical cap with the

sphere to reduce the wear

ci

ct

Pa

Study the possibility to have more efficiency

with a focusing ultrasonic beam on the contact
point by using a sphere

Sphere system - FEM simulation

Pa

28

Automation system

Glass fiber reinforced

polymer
Small scale of the
Beam
Monolithic element
Filament winding
process

Anthropomorphic robot
for scan
Air-coupled ultrasound
probes

Pc to control the robot

Triggering the ultrasound
signal
Plot in real time the twodimensional and threedimensional intensity
scan map
29

Scan map of the glass fiber beam

Automatic system which scans the total area of the component allowing a
complete structural integrity control including internal defects

2D map of the
ultrasound signal
amplitude

3D map

30

2nd Case study - Deck profile inspection

Concrete

Glass fiber reinforced

polymer 3-6 mm of
thickness

Hidden surface

Can be inspected using

thermography techniques

IR

5 mm

10 mm

10 mm

5 mm

31

Deck profile inspection

IR

load lamp

Frame with the best

contrast between the
defective area and non
defective area

mirror

To inspect hidden
surfaces the solution
can be the use of the
mirror (aluminum)

Temperature (k)

Thermal transient

Defects

Non defective
area
Defective
area
Frame

32

Infrared scan system

The scan system set up shows an anthropomorphic robot that move the
infrared camera, a load lamp and a mirror
Anthropomorphic
robot
Infrared camera
Load lamp

Acquisition system
Sample of inspection
33

Scan system configuration

The shape of the deck is complex and different configurations are
request to inspect all deck surfaces

Scan of bottom
surface

Scan of upper-left
surface

Scan of upper-right
surface

34

Simulated defect to validate the inspection

system
Simulated defect has been introduced to validate the inspection
system

Defects: flat washers

35

Infrared images
Infrared images showing defects obtained framing the surface
opposite to the one where the flat washers are attached

36

Conclusions
Ultrasonic and thermography systems have been identified as the best
techniques to inspect composite structural components for civil
application due to their flexibility, cost and performances.
Innovative configuration such as hybrid ultrasonic and thermography
with mirror have been studied to overcome the limits of inspection of
complex structures.
A spherical cap has been applied on the ultrasonic transducer in order
to increase the flexibility on curved profiles, rough surfaces and to
improve the spatial resolution.
Thanks to the first promising experimental results, a numerical
optimization of the spherical cap is in progress to optimize the system
37