X-rays take non-destructive testing in aeronautics to a whole new level
Carbon fibre-reinforced polymers or plastics (CFRPs) are lightweight, high-strength materials that have helped the aerospace industry cut fuel consumption and emissions without compromising performance. In fact, the next generation of aircraft is targeted to contain more than 50 % of composite materials. The range of components that can be formed from these materials continues to grow, encompassing designs of complex shape and internal structure. A revolutionary technology platform for non-destructive testing of aeronautic components is currently under way thanks to EU funding of the project QUICOM (Quantitative inspection of complex composite aeronautic parts using advanced X-ray techniques). Much as a medical doctor uses X-ray images for diagnosis, for example, aeronautic engineers use them to characterise the inner structure of a component. Scientists in this project have developed optimised image acquisition and image processing methodologies capable of analysing the pores, fibre and matrix components of the composites. In addition, simulation scenarios for small, high-volume CFRP parts were generated to represent the individual features as pores, resin, fibres and delamination, among others. A large variety of CT techniques were investigated to provide detailed information about the characteristics of the materials and components. These included robot-based CT, fast process integrated CT, multi-energy CT and high-resolution CT, as well as advanced X-ray techniques. For example, single-photon detection was successfully employed to obtain excellent images of composites with metallic inlays as well as sandwich structures with metal cores. Modelling of large and complex CFRP parts was also undertaken. A new method to calculate the absolute porosity of composites without using reference samples was developed as well. Finally, two different routes for the analysis and visualisation of results were developed and assessed. The project consortium successfully implemented the QUICOM technology platform as specified and demonstrated it to be functional in its various aspects at the end of the project. The different techniques will undergo a detailed testing and refinement phase to evaluate and enhance the potential for daily industrial use. QUICOM's technology platform is expected to revolutionise non-destructive testing of CFRP composites. Cost-effective and rapid access to detailed and non-destructive 3D characterisations will lift the EU aerospace industry to new heights.
Keywords
X-rays, non-destructive testing, aeronautics, CFRPs, technology platform, QUICOM
