Advanced Ultrasonic Imaging of Composite Repairs in Aero-Structures (AURORAS)

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Composite structures are increasingly utilised in aircraft for their stiffness, light weight and corrosion resistance but are sensitive to impact damage that can produce defects such delaminations . Damaged areas that are visible are repaired using an adhesively bonded composite repair method. The repair process is sensitive to process parameters and small variations will lead to defects that may result in reduced mechanical integrity. The inspection of composite repairs is difficult and not yet sufficiently developed to meet inspection quality requirements. AURORAS will develop the Phased Array Ultrasonic Test (PAUT) technique incorporating 3D imaging with high resolution 'Total Focusing Method' (TFM) to non-destructively assess the damage in aerostructure composite components. Once the damage has been classified and sized, an in-situ repair process will be undertaken and the repair will be re-inspected to detect defects using a similar PAUT technique optimised for the composite repair material. The main project deliverables will be a prototype system spec, 3D imaging & TFM software, a demonstration trial showing the PAUT method on composite repair components. repairomponents provided by the partners.