Download N04-262 TITLE: Automated Nondestructive Evaluation (NDE

N04-262
TITLE: Automated Nondestructive Evaluation (NDE) System for Finding Foreign Materials and Contaminants in
Manually Fabricated Composite Components
TECHNOLOGY AREAS: Materials/Processes
ACQUISITION PROGRAM: PMA-275, V-22
OBJECTIVE: Develop new innovative technologies or processes that would substantially reduce the inspection time to detect foreign
materials and contaminants in thick manual lay-ups for composite components.
DESCRIPTION: The cost associated with scrap/rework of composite components having foreign inclusions and contaminant-induced
defects is well documented. Insertion of detection/inspection technology capable of detecting foreign materials and contaminants
during the fabrication process will reduce these costs. Manual lay-ups for composite (fiberglass, graphite or a comination of the two)
components are up to 5 inches thick. Innovative semi-automated or automated processes are sought that are capable of detecting a
wide variety of foreign material and contaminants such as metal (steel, aluminum, etc.) polymers, ceramics, wood, and paper in the
composite lay-up. Proposed solutions should be able to detect foreign material and contaminates while the component is laying in a
steel mold or wrapped on a steel mandrel. The proposed systems should not contact the composite material with a tool or any kind of
couplant as the composite material is in the uncured state. The inspection system will be operated on a factory floor and must not
have any environmental or safety impact on nearby workers.
Insertion of this tecnology in the fabrication process (for example, prior to debulking) will enable correction by de-ply and should
reduce the defect population including foreign materials. Savings in cycle time and labor hours due to reduction of defects would be
substantial. Substantial costs associated with custom application of traceable backing materials (i.e., aluminized) could be eliminated.
PHASE I: Demonstrate the scientific merit and feasibility of detecting foreign materials in composite lay-ups. The inspection process
must not contact the composite or require removal of the composite from the metal manufacturing tooling.
PHASE II: Develop and optimize the proposed technology for the variety of composite material types, combinations, thickness
ranges, and tooling configurations. Demonstrate a working prototype under expected manufacturing floor conditions.
PHASE III: Refine the user interface and adapt the system for specific application(s). Develop an operating scenario and obtain
feedback so that the optimization criteria are formulated and applied. Ensure that beneficial data from the system are efficiently
routed, displayed, or recorded. Mitigate reliability issues.
PRIVATE SECTOR COMMERCIAL POTENTIAL: This technology will be most applicable to the manual lay-up process for
composite manufacturing such as that found in the aircraft or rotorcraft industry. It may also be applied to ship building and civil
infrastructure as well.
REFERENCES:
1. Harrouche, K., Rouvaen, J. M., Duquennoy, M., Ourak, M., and Ouafthouh, M. "Comparative Study of Processing Methods for
Analyzing the Structure of Carbon Epoxy Composite Materials." American Institute of Physics, Vol. 509, pp. 1191-1198.
KEYWORDS: NDE; NDI; Nondetructive Testing; Inspection; Composites; Hand Layup