Radome health management based on synthesized impact detection,laser ultrasonic spectral imaging,and wavelet-transformed ultrasonic propagation imaging methods

A radome must not only withstand various forces during operation, but also provide a window for electromagnetic signals. A radome is generally a composite sandwich structure. Much of the damage to radomes is barely visible to the naked eye on the outer surface, but is severe internally. In this study, a radome health management strategy consisting of in-flight damage event detection and ground damage evaluation processes is proposed. A radome health management system, composed of an on-board subsystem and a ground subsystem, was developed to realize the strategy. An in-flight event detection system was developed based on acoustic emission (AE) technology. A built-in amplifier-integrated PZT sensor was used, and the minimum impact energy that the on-board subsystem can detect was determined. The AE sensor was then switched to an ultrasonic receiver. A scanning laser ultrasonic technology was combined with the ultrasonic receiver to develop a ground nondestructive evaluation subsystem. For in situ damage visualization, laser ultrasonic frequency tomography and wavelet-transformed ultrasonic propagation imaging algorithms were developed in this study. To demonstrate the robustness of the ground subsystem, a damage was generated by 5.42 J impact in a glass/epoxy radome with honeycomb core, and the impact image of 25 mm in diameter invisible outside could be visualized with the combination of ultrasonic spectral imaging (USI) and wavelet-transformed ultrasonic propagation imaging (WUPI), which made the propagation of only the damage-related ultrasonic modes visible.     

Effect of temperature on low velocity impact damage and post-impact flexural strength of CFRP assessed using ultrasonic C-scan and micro-focus computed tomography

The effect of temperature on the low velocity impact resistance properties and on the post-impact flexural performance of CFRP laminates were studied. With this aim, 150 × 75 mm cross-ply carbon fibre/epoxy laminates with a [0/90/90/0]_2s layup, therefore with a total of sixteen layers, were impacted at ambient temperature (30 °C) and at elevated temperatures (55, 75 and 90 °C) at a velocity of 2 m/s using a drop weight impact tower. This was followed by flexural tests carried out at ambient temperature using a three-point bending rig. Damage assessment of impact and post-impact behaviour were carried out using ultrasonic C-scan and microfocus X-ray computed tomography (μCT). Interrupted flexural tests using μCT allowed delamination propagation to be observed. In general, lower projected damage was observed at elevated temperatures, which resulted also in a possible hindrance to delamination and shear cracks propagation during impact and in a greater amount of retained flexural strength after impact.     

Strain and damage monitoring of CFRP in impact loading using a fiber Bragg grating sensor system

A fiber-optic system featuring strain measurement and ultrasonic detection was constructed with fiber Bragg gratings based on wavelength–light intensity conversion technique. This fiber Bragg grating sensing system consists of a broadband light source, a broadband optical filter for strain measurement and a narrowband tunable filter for ultrasonic detection. The system was applied to strain measurement in impact loading to carbon fiber-reinforced plastics and the subsequent impact damage detection. Experimental results demonstrated that fiber Bragg grating sensors could measure strain with higher resolution compared with conventional strain gauges. Furthermore, ultrasonic inspection in which ultrasonic sensitivity was maximized by controlling the transmissive wavelength of the tunable filter could detect a 6.3 × 9 mm² impact damage.     

A new method of semi-continuous casting of AZ80 Mg alloy billets by a combination of electromagnetic and ultrasonic fields

The influence of low frequency electromagnetic field and power ultrasonic field on the microstructure of AZ80 Mg alloy billets was studied. The magnetic flux density and time average electromagnetic volume force density were obtained by numerical simulation. The acoustic pressure distribution was also numerically calculated in order to characterize the ultrasonic field propagation. After comparison of the different effects of grain refinement by low frequency electromagnetic casting (LFEC) and ultrasonic casting (UC), a new method (LFEC + UC) was developed by simultaneously applying ultrasonic vibration to the melt during low frequency electromagnetic semi-continuous casting of AZ80 Mg alloy billets. With the application of the compound field under the optimum conditions, the as-cast macrostructure and microstructure were refined and homogeneously distributed. An obvious improvement of mechanical properties was finally obtained. The mechanisms of grain refinement and interaction of low frequency electromagnetic field and power ultrasonic field with the melt were discussed.     

The influence of preload and boundary conditions on pre-damaged composite plates subject to soft-body impact

This research investigates the influence of preload and boundary condition compliance on low-velocity impact damaged CFRP T800S/3900-2B plates subject to secondary higher-velocity soft-body impact (50 J, 75 J, 100 J). A bilinear cohesive element based delamination model combined with ply-based composite material failure was developed using LS-DYNA 971. Double Cantilever Beam (DCB), 3-point End-Notched Flexure (ENF), and Fixed Ratio Mixed Mode Bending (FRMMB) simulations validate the accuracy of the delamination model when compared with theory. The low-velocity impact simulations were shown to compare well with the results of drop-tower impact experiments and ultrasonic inspection data in terms of maximum impact force and projected delamination area. An investigation of boundary condition compliance in the direction of impact showed a reduction in peak impact force, interlaminar delamination and intralaminar failure with increasing coupon translation. High-velocity impact simulations based on the model with initial damage showed a reduction in interlaminar delamination damage with tensile preload when compared to compressive preload and unloaded cases for all impact energies.     

Relating damage evolution of concrete cooled to cryogenic temperatures to permeability

Typically, 9% Ni steel is used for primary containment of liquefied natural gas (LNG). Utilization of concrete in place of 9% Ni steel for primary containment would lead to significant cost savings. Hence, this study investigates changes in the microstructure of concrete due to cryogenic freezing that would affect its relevant engineering properties for containment. The study also evaluates the effect of aggregate type on the damage potential of concrete subjected to cryogenic freezing. The aim is to investigate design methodologies to produce damage-resistant cryogenic concrete. The study employed four concrete mixture designs involving river sand as fine aggregate, and coarse aggregates with different coefficient of thermal expansion (CTE) values. Specifically, the coarse aggregates were limestone, sandstone, trap rock and lightweight aggregate. Concrete cubes were cured under water for at least 28 days and thereafter frozen from ambient (20 °C) to cryogenic temperature (−165 °C). Acoustic emission (AE) sensors were placed on the concrete cubes during freezing. X-ray computed tomography (XRCT) was employed to study the microstructure of concrete cores, before and after cryogenic freezing. The impact of the microstructural evolution thus obtained from AE and XRCT on relevant engineering properties was determined via water and chloride permeability tests. Microcrack propagation determined from AE correlated with changes in permeability. There were no observable cracks in majority of the concrete mixtures after freezing. This implies that microcracks detected via AE and increased permeability was very well distributed and smaller than the XRCT’s resolution. Damage (microcracking) resistance of the concrete with different aggregates was in the order limestone ⩾ trap rock ≫ lightweight aggregate ⩾ sandstone.     

Influence of temperature, [Ca2+], Ca/P ratio and ultrasonic power on the crystallinity and morphology of hydroxyapatite nanoparticles prepared with a novel ultrasonic precipitation method

Nanocrystalline hydroxyapatite was prepared by a precipitation method with the aid of ultrasonic irradiation using Ca(NO₃)₂ and NH₄H₂PO₄ as source material and carbamide (NH₂CONH₂) as precipitator. The influence of Ca/P molar ratio, precipitation temperature, concentration of Ca²⁺ ([Ca²⁺]) and ultrasonic power on the crystallinity of the nanopowder were systematically investigated by XRD analysis. The size of the as-prepared particles was analyzed using TEM and XRD methods. The results revealed that the monophase hydroxyapatite could be obtained at the following technological conditions: [Ca²⁺] = 0.01–0.1 mol/L, ultrasonic power = 300 W, Ca/P (mol) = 1.2–2.5 and T = 313–353 K. In addition, the acicular and spherical particles could be prepared at different ultrasonic powers of 300 and 200 W, respectively.     

Post-impact damage characterization of hybrid configurations of jute/glass polyester laminates using acoustic emission and IR thermography

In this work, residual post-impact properties of two configurations of E-glass/jute hybrid laminates are characterized, both manufactured using a total fibre volume of 50 ± 2% (14 glass fibre layers + 4 jute fibre layers). T-laminates included a core obtained by multiple layers of jute between two E-glass fibre reinforced skins, whilst in Q-laminates single layers of jute fibres were intercalated at different levels between E-glass fibre reinforced layers. All laminates were impacted at five levels of energy, from 5 to 15 J, and then subjected to post-impact flexural tests.The results suggest that T hybrids perform better at low impact energies (up to 10 J), which do not damage significantly the laminate core. In contrast, Q hybrids are better suited to withstand extensive damage produced by higher impact energies (12.5 and 15 J), in that they allow a more effective redistribution of impact damage in the structure. This was confirmed by acoustic emission (AE) monitoring during flexural loading, which offered indications on the maximum stress laminates can undergo after impact damage. Pulse IR thermography yielded information on their mode of failure by visualizing impact-damaged areas.     

Mechanical damage characterization of glass fiber-reinforced polymer laminates by ultrasonic maps

A method for simultaneous measurement of the thickness and density for Glass Fiber-Reinforced Polymer (GFRP) laminate plates with ultrasonic waves in C-Scan mode is presented in the form of maps. The method uses three different signals in immersion pulse-echo C-Scan mode. The maps obtained based on the density show the heterogeneity of the material at high resolution at the pixel level (1 × 1 mm²) and therefore they represent an efficient tool to assess and evaluate the damage of the composite structures after manufacturing and after an applied mechanical loading.     

Mechanical behaviour of jute cloth/wool felts hybrid laminates

This experimental work is aimed at the characterization of new fibre reinforced composites based on epoxy resin with both protein (wool) and lignocellulosic (jute) natural fibres. Wool-based and hybrid (wool/jute) composites with two different stacking sequences (intercalated and sandwich) were developed. Their microstructure has been investigated through optical and scanning electron microscopy, whereas their quasi-static mechanical behaviour has been evaluated in tension and bending. In addition, the impact behaviour under low-velocity impact at three different impact energies, namely 6 J, 8 J and 9 J has been addressed. The tensile and flexural tests have been monitored using acoustic emission (AE) in order to elicit further information about failure mechanisms. AE monitoring showed that development of damage was due to nucleation of matrix microcracks and subsequent debonding and pull-out phenomena in wool fibre composites and that only in hybrid composites a sufficient stress transfer across the jute fibre/matrix interface was achieved. The results confirmed the positive role of hybridization with jute fibres in enhancing both the tensile and flexural behaviour of wool-based composites, though highlighting the need for an improved adhesion between wool fibres and epoxy matrix.     

The ultrasonic and image analysis method for non-destructive quantification of the thermal shock damage in refractory specimens

In the present work, Mg-exchanged zeolit and silicon carbide were used as starting materials for obtaining cordierite/SiC composite ceramics with weight ratio 50:50.Samples were exposed to the water quench test from 950 °C, applying various number of thermal cycles (shocks). Level of surface deterioration before and during quenching was monitored by image analysis. Ultrasonic measurements were used as non-destructive quantification of thermal shock damage in refractory specimens. When refractory samples are subjected to the rapid temperature changes crack nucleation and propagation occurs resulting in loss of strength and materials degradation. The formation of cracks decreases the density and elastic properties of material. Therefore measuring these properties can directly monitor the development of thermal shock damage level. Dynamic Young modulus of elasticity and strength degradation were calculated using measured values of ultrasonic velocities obtained by ultrasonic measurements. Level of degradation of the samples was monitored using Image Pro Plus program for image analysis. The capability of non-destructive test methods such are: ultrasonic velocity technique and image analysis for simple, and reliable non-destructive methods of characterization were presented in this paper.     

The influence of binder tow density on the mechanical properties of spatially reinforced composites. Part 1 – Impact resistance

This paper examines the influence of binder tow stitch density on the impact performance of advanced composite structures. Spatially reinforced composite reinforcements with multi-axis, multi-layer structures were woven on a specially developed loom. The binder tow stitch density, which was used to consolidate the structure, was varied in the range of 1–4 binder tow stitches/cm² (10 × 10 mm to 5 × 5 mm binder tow stitch spacing). A drop weight impact test (6.7 J/mm of composite thickness) was used to damage the samples. Both the depth of penetration and the damage area were measured after impact. The analysis of the results has shown that as the binder tow stitch density was increased the extent of damage decreased. The weave architecture, in terms of the relative position of the ±45° tows, was also shown to be a significant factor, the nearer the off-axis tows are to the impact surface the greater was the damage area.     

Acoustic emission waveform characterization of crack origin and mode in fractured and ASR damaged concrete

Different constituents of concrete can have cracking behavior that varies in terms of the acoustic waveform that is generated. Understanding the waveform may provide insight into the source and behavior of a crack that occurs in a cementitious composite. In this study, passive acoustic emission (AE) was used to investigate the waveform properties of the individual components of concrete (i.e., aggregate, paste, and interfacial transition zone (ITZ)). First, acoustic events produced by cracks generated using mechanical loading in a wedge splitting test were detected. It was observed that cracks that occurred through the aggregate have an AE frequency range between 300 kHz and 400 kHz, while cracks that propagated through the matrix (paste and ITZ) have a frequency range between 100 kHz and 300 kHz. Second, tests were performed using samples that were susceptible to alkali silica reaction; and AE and X-ray computed tomography were used to detect cracking. AE events with a frequency range between 300 kHz and 400 kHz were detected at early ages, suggesting the initiation of cracks within reactive aggregate. At later ages, AE events were detected with frequency ranges of 100–300 kHz, indicating crack development and propagation in the matrix.     

Non-destructive evaluation of concrete mixtures for direct LNG containment

The suitability of six concrete mixtures for use in direct containment of liquefied natural gas (LNG) was assessed using nuclear magnetic resonance (NMR), X-ray computed tomography (XRCT) and acoustic emission (AE). The mixtures were prepared with river sand as fine aggregate using different coarse aggregates. The mixtures were cooled from ambient to cryogenic temperatures at a cooling rate of 3 °C/min. Proton NMR measurements and XRCT imaging were carried out before and after cooling to monitor changes in porosity and pore size distribution, and internal microstructure, respectively. AE sensors monitored damage evolution during cooling and warming. NMR results indicated porosity increases of 0%, 0.3%, 1.4% and 3.3% in the non-air-entrained trap rock aggregate, limestone aggregate, sandstone aggregate and lightweight aggregate concrete mixtures, respectively. The air-entrained trap rock and limestone mixtures showed porosity increases of 0% and 1.9%, respectively. There was a strong positive correlation between AE cumulative energy and NMR porosity change. XRCT imaging generally showed no frost-induced cracking in the concrete mixtures. Thus, pore structure changes and apparent damage were in the form of microcracks less than the XRCT resolution (22 microns). The results highlight the utility of trap rock aggregate in production of durable concrete for direct LNG containment.     

Fabrication of continuous carbon fiber-reinforced aluminum–magnesium alloy composite wires using ultrasonic infiltration method

In order to fabricate continuous carbon fiber-reinforced aluminum alloy matrix composites, various infiltration methods such as gas pressure infiltration, CVD-infiltration, and ultrasonic infiltration methods have been developed. Among these methods, the ultrasonic infiltration method is the simplest. In this study, the effects of ultrasonic power, the diameter of the hole of the horn, fabricating speed, and magnesium content on the ease of infiltration are investigated. As the results, both an ultrasonic power of 200 W and the addition of more than 2.4 mass% Mg are indispensable to infiltrate molten aluminum alloy into a PAN-based M40J carbon fiber bundle, which has 6000 filaments. Contrariwise, the tensile strength and relative strength (ROM ratio) of the obtained composites decreased from 1100 MPa (0.7) at both 2.4 and 4.7 mass% Mg contents to 800 MPa (0.5) at 10 mass% Mg content. This was probably caused by an increase in the content of the Al₃Mg₂ intermetallic compound. Consequently, the addition of magnesium is effective in improving the infiltration; however, it causes the strength of the composites to decrease. It is found that in this process, the optimum magnesium content in aluminum from the viewpoints of ease of infiltration and strength was 4.7 mass%.     

Rapid synthesis of cryptomelane-type manganese oxide under ultrasonic process

Cryptomelane-type manganese oxide (OMS-2) was rapidly prepared under ultrasonic irradiation in short time. Characterization results using X-ray powder diffraction (XRD), surface area analyzer, transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), oxygen temperature-programmed desorption (O₂-TPD) revealed that ultrasonic irradiation has tremendous effect on the surface area, morphology, surface defects, and redox properties of the OMS-2 materials. The OMS-2 prepared via ultrasonic irradiation shows nanoneedle morphology with smaller crystallite size, larger surface area (120.4 m²/g), more surface defects, and higher oxygen mobility, thus it demonstrates excellent activity in the catalytic combustion of dimethyl ether with a start-off temperature of 160 °C and a complete combustion temperature of 172 °C.     

Drop-weight impact of plain-woven hybrid glass–graphite/toughened epoxy composites

The progressive damage behaviors of hybrid woven composite panels (101.6 mm × 101.6 mm) impacted by drop-weights at four different velocities were studied by a combined experimental and 3-D dynamic nonlinear finite element approach. The specimens tested were made of plain-weave hybrid S2 glass-IM7 graphite fibers/toughened epoxy (cured at 177 °C). The composite panels were damaged using a pressure-assisted Instron-Dynatup 8520 instrumented drop-weight impact tester. During these low-velocity simpact tests, the time-histories of impact-induced dynamic strains and impact forces were recorded. The damaged specimens were inspected visually and using ultrasonic C-Scan methods. The commercially available 3-D dynamic nonlinear finite element (FE) software, LS-DYNA, incorporated with a proposed user-defined damage-induced nonlinear orthotropic model, was then used to simulate the experimental results of drop-weight tests. Good agreement between experimental and FE results has been achieved when comparing dynamic force, strain histories and damage patterns from experimental measurements and FE simulations.     

Preparation of Al matrix nanocomposites by diluting the composite granules containing nano-SiCp under ultrasonic vibaration

In this work, an efficient process by diluting the nano-SiCp/Al composite granules in the molten matrix under ultrasonic vibration(UV) was developed to prepare metal matrix nano-composites(MMNCs).Millimeter-sized composite granules with high content of SiC particle(8 wt%) were specially fabricated by dry high-energy ball milling(HBM) without process control agent, and then remelted and diluted in molten Al alloy under UV. The MMNCs melt was finally squeeze cast under a squeeze pressure of 200 MPa, Microstructure of the composite granules during dry HBM was investigated, and the effect of UV on microstructure and mechanical properties of the MMNCs was discussed. The results indicate that nano-SiC particles are uniformly distributed in the nano-SiCp/Al composite granules, which are covered by vestures of pure Al. During diluting, nano-SiC particles released from the composite granules are quickly dispersed in the molten matrix by UV within 4 min. Microstructure of MMNCs is significantly refined under UV and squeeze casting, eutectic Si phase modified to fine islands with an average length of 1.4 μm. Tensile strength of the squeeze cast MMNCs with 1 wt% of nano-SiC particles is 269 MPa, which is improved by 25% compared with the A356 alloy matrix.     

Investigation of the response to low velocity impact and quasi-static indentation loading of particle-toughened carbon-fibre composite materials

This work investigates damage caused by low velocity impact and quasi-static indentation loading in four different particle-toughened composite systems, and one untoughened system. For impact tests, a range of energies were used between 25 and 50 J. For QSI, coupons were interrupted at increasing loading point displacement levels from 2 to 5 mm to allow for monitoring of damage initiation and propagation. In both loading cases, non-destructive inspection techniques were used, consisting of ultrasonic C-scan and X-ray micro-focus computed tomography. These techniques are complemented with instrumentation to capture force–displacement data, whereby load-drops are associated with observed damage modes. Key results from this work highlight particular issues regarding strain-rate sensitivity of delamination development and an earlier onset of fibre fracture associated with particle-toughened systems. These issues, in addition to observations on the role of micro-scale events on damage morphology, are discussed with a focus on material development and material testing practices.     

Carbon/epoxy composite delamination analysis by acoustic emission method under various environmental conditions

New multifunctional materials for aerospace industry with exceptional properties must be tested under various environmental conditions to find out possible scatter factors for evaluated properties. Delamination is a typical damage mode observed for laminated composites. Therefore, reliable information regarding the delamination growth behaviour is needed for all operational environments of an aircraft operated at cryogenic and elevated temperatures. In this paper, delamination crack growth monitoring in a climatic chamber on double-cantilever beam (DCB) specimens using optical devices and acoustic emission (AE) techniques is described. A relationship between cumulative AE energy, events localization, clusters, and crack growth in a plain-weave carbon fibre–reinforced epoxy is investigated under constant displacement rate loading at + 80 °C, and − 55 °C. Test results are evaluated for specimens with multi-walled carbon nanotubes (MWCNT) in the microstructure and for a reference material. The mechanical properties during delamination are represented by fracture toughness G_IC, and they are also correlated with the AE data. The elevated test temperature caused a decreased rate of released AE energy. The crack growth in material with more significant fibre breakage caused increase of the AE release rate.