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Thermography has been shown to be a viable technique for inspection of composites. Impact damage in composites typically contains multiple overlapping delaminations at different depths. Understanding the limitations of the thermographic inspection is enhanced by performing simulations of the technique. Most simulations of composite thermographic inspections have focused on simulations of a single delamination at a fixed depth. The quadrupole method has been shown as a viable technique for rapid three-dimensional thermographic simulations of a delamination. This method is expanded to enable rapid simulation of multiple overlapping delaminations at different depths. Quadrupole simulations are compared to finite element simulations of multiple delaminations at different depths. The simulations are also compared to the thermographic measurements on impacted composites where shape and depth of the delaminations are known from x-ray computed tomography data.

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in a composite hat-stiffened panel during quasi-static loading. The heating is composed of two heat generation components. The first component is an instantaneous response due to a strain release during quasi-static loading. The second component is mechanical heating, at the interface of failure, due to fracture damage. This second component produces a transient rise in temperature that is a function of the damage depth and thermal diffusivity. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is used to determine the damage depth. The results are compared to ultrasonic and X-ray CT data. The advantages and limitations of the thermal technique for damage depth detection are discussed.

The purpose of this paper is to describe the methodology of measuring damage onset and growth in a composite structure during quasi-static loading using passive thermography and acoustic emission. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which resulted in the formation of damage between the stiffener flange and skin. The loading was stopped when damage growth was detected. Passive thermography and acoustic emission were used to detect damage in real-time as a function of the applied load. Of particular interest are the small transient thermographic signals resulting from damage formation which can be challenging to detect, as compared to the persistent passive thermography indications of cyclic fatigue loading. We describe a custom developed thermal inspection system for detection of composite damage during quasi-static loading. The thermal results are compared to a two-dimensional multi-layered thermal simulation based on the quadrupole method. Acoustic emission is used to further characterize the damage by comparing the acoustic emission events with the thermal imagery. Results are compared to ultrasonic measurements to document the damage through-the-thickness.

Real time nondestructive evaluation is required for composites load testing. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which can result in the formation of delamination damage between the stiffener flange and skin. Passive thermography was used to detect damage in real time as a function of the applied load. The loading was stopped when damage growth was detected. Of particular interest was the early detection of damage formation which can be challenging, as compared to cyclic fatigue loading. Passive thermography data were acquired and processed in real time and revealed damaged areas due to heating from fiber breakage and delamination formation. The processed thermal imagery was also compared to acoustic emission and ultrasound data.

A composite fuselage aircraft forward section was inspected with flash thermography. The fuselage section is 24 feet long and approximately 8 feet in diameter. The structure is primarily configured with a composite sandwich structure of carbon fiber face sheets with a Nomex(Trademark) honeycomb core. The outer surface area was inspected. The thermal data consisted of 477 data sets totaling in size of over 227 Gigabytes. Principal component analysis (PCA) was used to process the data sets for substructure and defect detection. A fixed eigenvector approach using a global covariance matrix was used and compared to a varying eigenvector approach. The fixed eigenvector approach was demonstrated to be a practical analysis method for the detection and interpretation of various defects such as paint thickness variation, possible water intrusion damage, and delamination damage. In addition, inspection considerations are discussed including coordinate system layout, manipulation of the fuselage section, and the manual scanning technique used for full coverage.

Passive thermography has been shown to be an effective method for in-situ and real time nondestructive evaluation (NDE) to measure damage growth in a composite structure during cyclic loading. The heat generation by subsurface flaw results in a measurable thermal profile at the surface. This paper models the heat generation as a planar subsurface source and calculates the resultant temperature profile at the surface using a three dimensional quadrupole. The results of the model are compared to finite element simulations of the same planar sources and experimental data acquired during cyclic loading of composite specimens.

Large area nondestructive evaluation (NDE) inspections are required for fatigue testing of composite structures to track damage initiation and growth. Of particular interest is the progression of damage leading to ultimate failure to validate damage progression models. In this work, passive thermography and acoustic emission NDE were used to track damage growth up to failure of a composite three-stringer panel. Fourteen acoustic emission sensors were placed on the composite panel. The signals from the array were acquired simultaneously and allowed for acoustic emission location. In addition, real time thermal data of the composite structure were acquired during loading. Details are presented on the mapping of the acoustic emission locations directly onto the thermal imagery to confirm areas of damage growth leading to ultimate failure. This required synchronizing the acoustic emission and thermal data with the applied loading. In addition, processing of the thermal imagery which included contrast enhancement, removal of optical barrel distortion and correction of angular rotation before mapping the acoustic event locations are discussed.

A method for inspecting a structural sample using ultrasonic energy includes positioning an ultrasonic transducer adjacent to a surface of the sample, and then transmitting ultrasonic energy into the sample. Force pulses are applied to the transducer concurrently with transmission of the ultrasonic energy. A host machine processes ultrasonic return pulses from an ultrasonic pulser/receiver to quantify attenuation of the ultrasonic energy within the sample. The host machine detects a defect in the sample using the quantified level of attenuation. The method may include positioning a dry couplant between an ultrasonic transducer and the surface. A system includes an actuator, an ultrasonic transducer, a dry couplant between the transducer the sample, a scanning device that moves the actuator and transducer, and a measurement system having a pulsed actuator power supply, an ultrasonic pulser/receiver, and a host machine that executes the above method.

The application of the quadrupole method for simulating thermal responses of delaminations in carbon fiber reinforced epoxy composites materials is presented. The method solves for the flux at the interface containing the delamination. From the interface flux, the temperature at the surface is calculated. While the results presented are for single sided measurements, with ash heating, expansion of the technique to arbitrary temporal flux heating or through transmission measurements is simple. The quadrupole method is shown to have two distinct advantages relative to finite element or finite difference techniques. First, it is straight forward to incorporate arbitrary shaped delaminations into the simulation. Second, the quadrupole method enables calculation of the thermal response at only the times of interest. This, combined with a significant reduction in the number of degrees of freedom for the same simulation quality, results in a reduction of the computation time by at least an order of magnitude. Therefore, it is a more viable technique for model based inversion of thermographic data. Results for simulations of delaminations in composites are presented and compared to measurements and finite element method results.

Passive thermography and acoustic emission data were obtained for improved real time damage detection during fatigue loading. A strong positive correlation was demonstrated between acoustic energy event location and thermal heating, especially if the structure under load was nearing ultimate failure. An image processing routine was developed to map the acoustic emission data onto the thermal imagery. This required removing optical barrel distortion and angular rotation from the thermal data. The acoustic emission data were then mapped onto thermal data, revealing the cluster of acoustic emission event locations around the thermal signatures of interest. By combining both techniques, progression of damage growth is confirmed and areas of failure are identified. This technology provides improved real time inspections of advanced composite structures during fatigue testing.Keywords: Thermal nondestructive evaluation, fatigue damage detection, aerospace composite inspection, acoustic emission, passive thermography

Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF3) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF3 system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.

The use of composite materials continues to increase in the aerospace community due to the potential benefits of reduced weight, increased strength, and manufacturability. Ongoing work at NASA involves the use of the large-scale composite structures for spacecraft (payload shrouds, cryotanks, crew modules, etc). NASA is also working to enable the use and certification of composites in aircraft structures through the Advanced Composites Project (ACP). The rapid, in situ characterization of a wide range of the composite materials and structures has become a critical concern for the industry. In many applications it is necessary to monitor changes in these materials over a long time. The quantitative characterization of composite defects such as fiber waviness, reduced bond strength, delamination damage, and microcracking are of particular interest. The research approaches of NASA's Nondestructive Evaluation Sciences Branch include investigation of conventional, guided wave, and phase sensitive ultrasonic methods, infrared thermography and x-ray computed tomography techniques. The use of simulation tools for optimizing and developing these methods is also an active area of research. This paper will focus on current research activities related to large area NDE for rapidly characterizing aerospace composites.

Numerical simulations of thermographic responses in composite materials have been a useful for evaluating and optimizing thermographic analysis techniques. Numerical solutions are particularly beneficial for thermographic techniques, since the fabrication of specimens with realistic flaws is difficult. Simulations are presented with different ply layups that incorporated the anisotropic thermal properties that exist in each ply. The results are compared to analytical series solutions and thermal measurements on composites with flat bottom holes and delaminations.

Simple methods for reducing the pulsed thermographic responses of flaws have tended to be based on either the spatial or temporal response. This independent assessment limits the accuracy of characterization. A variational approach is presented for reducing the thermographic data to produce an estimated size for a flaw that incorporates both the temporal and spatial response to improve the characterization. The size and depth are determined from both the temporal and spatial thermal response of the exterior surface above a flaw and constraints on the length of the contour surrounding the delamination. Examples of the application of the technique to simulation and experimental data acquired are presented to investigate the limitations of the technique.

Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. While a reliable technique for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from composite materials. This method has been applied for characterization of flaws.

Simple methods for reducing the pulsed thermographic responses of delaminations tend to overestimate the size of the delamination, since the heat diffuses in the plane parallel to the surface. The result is a temperature profile over the delamination which is larger than the delamination size. A variational approach is presented for reducing the thermographic data to produce an estimated size for a flaw that is much closer to the true size of the delamination. The method is based on an estimate for the thermal response that is a convolution of a Gaussian kernel with the shape of the flaw. The size is determined from both the temporal and spatial thermal response of the exterior surface above the delamination and constraints on the length of the contour surrounding the delamination. Examples of the application of the technique to simulation and experimental data are presented to investigate the limitations of the technique.

Fatigue testing of advanced composite structures is critical to validate both structural designs and damage prediction models. In-situ inspection methods are necessary to track damage onset and growth as a function of load cycles. Passive thermography is a large area, noncontact inspection technique that is used to detect composite damage onset and growth in real time as a function of fatigue cycles. The thermal images are acquired in synchronicity to the applied compressive load using a dual infrared camera acquisition system for full (front and back) coverage. Image processing algorithms are investigated to increase defect contrast areas. The thermal results are compared to non-immersion ultrasound inspections and acoustic emission data.

Composite honeycomb structures are widely used in aerospace applications due to their low weight and high strength advantages. Developing nondestructive evaluation (NDE) inspection methods are essential for their safe performance. Flash thermography is a commonly used technique for composite honeycomb structure inspections due to its large area and rapid inspection capability. Flash thermography is shown to be sensitive for detection of face sheet impact damage and face sheet to core disbond. Data processing techniques, using principal component analysis to improve the defect contrast, are discussed. Limitations to the thermal detection of the core are investigated. In addition to flash thermography, X-ray computed tomography is used. The aluminum honeycomb core provides excellent X-ray contrast compared to the composite face sheet. The X-ray CT technique was used to detect impact damage, core crushing, and skin to core disbonds. Additionally, the X-ray CT technique is used to validate the thermography results.

The durability and damage tolerance of postbuckled composite structures are not yet completely understood, and remain difficult to predict due to the nonlinearity of the geometric response and its interaction with local damage modes. A research effort was conducted to investigate experimentally the quasi-static and fatigue damage progression in a single-stringer compression (SSC) specimen. Three specimens were manufactured with a hat-stiffener, and an initial defect was introduced with a Teflon film embedded between one flange of the stringer and the skin. One of the specimens was tested under quasi-static compressive loading, while the remaining two specimens were tested by cycling in postbuckling. The tests were performed at the NASA Langley Research Center under controlled conditions and with instrumentation that allows a precise evaluation of the postbuckling response and of the damage modes. Three-dimensional digital image correlation VIC-3D systems were used to provide full field displacements and strains on the skin and the stringer. Passive thermal monitoring was conducted during the fatigue tests using an infrared camera that showed the location of the delamination front while the specimen was being cycled. The live information from the thermography was used to stop the fatigue tests at critical stages of the damage evolution to allow detailed ultrasonic scans.

Conventional methods for reducing the pulsed thermographic responses of delaminations tend to overestimate the size of the flaw. Since the heat diffuses in the plane parallel to the surface, the resulting temperature profile over the flaw is larger than the flaw. A variational method is presented for reducing the thermographic data to produce an estimated size for the flaw that is much closer to the true size of the flaw. The size is determined from the spatial thermal response of the exterior surface above the flaw and a constraint on the length of the contour surrounding the flaw. The technique is applied to experimental data acquired on a flat bottom hole composite specimen.

Composite honeycomb structures continue to be widely used in aerospace applications due to their low weight and high strength advantages. Developing nondestructive evaluation (NDE) inspection methods are essential for their safe performance. Pulsed thermography is a commonly used technique for composite honeycomb structure inspections due to its large area and rapid inspection capability. Pulsed thermography is shown to be sensitive for detection of face sheet impact damage and face sheet to core disbond. Data processing techniques, using principal component analysis to improve the defect contrast, are presented. In addition, limitations to the thermal detection of the core are investigated. Other NDE techniques, such as computed tomography X-ray and ultrasound, are used for comparison to the thermography results.

Flaw detection and characterization with thermographic techniques in graphite polymer composites are often limited by localized variations in the thermographic response. Variations in properties such as acceptable porosity, fiber volume content and surface polymer thickness result in variations in the thermal response that in general cause significant variations in the initial thermal response. These result in a "noise" floor that increases the difficulty of detecting and characterizing deeper flaws. A method is presented for computationally removing a significant amount of the "noise" from near surface porosity by diffusing the early time response, then subtracting it from subsequent responses. Simulations of the thermal response of a composite are utilized in defining the limitations of the technique. This method for reducing the data is shown to give considerable improvement characterizing both the size and depth of damage. Examples are shown for data acquired on specimens with fabricated delaminations and impact damage.

Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.