Non-Destructive Evaluation of Aerospace Composites at the Manufacturing Stage

传统上，无损评估（NDE）部署在航空航天中的碳纤维增强聚合物（CFRP）的制造后阶段，如果发现有缺陷，则对成品部件进行维修/报废（报废）。然而，通过在中间工艺阶段部署NDE获得的半成品部件的知识将允许检测缺陷的来源并采取现场纠正工艺调整步骤，例如纤维编织、织物铺叠、树脂灌注的参数细化，这防止了在制造有缺陷的航空航天部件上花费时间和成本，所述航空航天部件通常尺寸非常大并且由鉴于不同无损检测模式的优点和缺点，该工程设计项目旨在：a）研究工业合作伙伴（Spirit AeroSystems）的典型CFRP产品的制造，B）识别常见工艺缺陷类型，位置和尺寸的性质，c）通过建模和实验，在比较研究中调查不同无损检测模式在每个制造阶段的优点和缺点d）提供可能的创新性无损检测模式，部署和传感器，以提高每个阶段的检测性能

Traditionally, Non-Destructive Evaluations (NDE) is deployed at post-manufacturing stage of Carbon Fiber Reinforced Polymers (CFRP) in aerospace where the finished components are repaired/rejected (scraped) if they are found to have defects. However, a knowledge of semi-finished components gained through deployment of NDE at intermediate process stages would allow detection of the source of defects and taking in-situ corrective process adjustment steps, such as parameters refinement for fiber weaving, fabric lay-up, resin infusion, etc. This prevents expenditure of time and costs on manufacturing of flawed aerospace components which are typically very large in size and made up of a considerable amount of raw material.In view of the strengths and weaknesses of different NDE modalities, this EngD project aims to:a) Study the manufacturing of typical CFRP products of the industrial partner (Spirit AeroSystems)b) Identify the nature of common process defect types, location, and size, c) Investigate the strengths and shortcomings of different NDE modalities for each manufacturing stage in a comparative study through modelling and experimentsd) Provide possible innovative alteration of NDE modality, deployment, and sensors for improved detection performance at each stage