presentation at 2011 maus user group meeting , … at 2011...presentation at 2011 maus user group...
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Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
1
Detecting Corrosion and Cracks
Hidden in Thick and Multiple Layer
Structures
Potential New Functions Added to
MAUS by Using GRFEC Technique
Yushi Sun, Tianhe Ouyang, Harry Zhu, Weiqiang Wan &
Changhong Sun
Innovative Materials Testing Technologies, Inc.
9769 W. 119th Drive, Suite 27
Broomfield, CO 80021
Tel: 303 554 8000, Email: [email protected]
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Fundamental Requirement for
Aircraft High Velocity Maintenance
NDI:
Detection of flaws without a need
of structure disassembly
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Least Preconditions for Techniques Enabling
HVM or
Flaw Detection without Structure Removal
1. Penetrating through whole thickness of structure;
2. Penetrating through interface gaps between
structure layers;
3. Access only on one side of structure.
4. Reliable algorithm to differentiate flaw from aircraft
structure variations
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Techniques EC UT X Ray GRFEC
Deep
penetration - √ √ √Thru
interface
gaps√ - √ √
Access one
side only √ √ - √
Capabilities
Technique Capability Comparison
of commonly use NDI methods
GRFEC is the best choice
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Presentation/Demonstration Content
1. Corrosion detection:
Detecting hidden corrosion on a aluminium plate that is
hidden a thick multi-layer aluminium stack with a up to 0.690”
thickness
• Using a GRFEC sliding probe
2. Crack detection:
Detecting lower layer EDM notches through a up to 0.500”
thick aluminium upper layer structure
• Using a GRFEC ring probe
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Brief Introduction of
GRFEC Technique and
SSEC III Instrument
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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RFEC for Tube Applications
Defects on tube wall can be detected by Pickup Coil away from Excitation Coil
• Two coupling paths
1) direct coupling path which decays faster
2) Indirect coupling path which decays slower
– Since the directly coupled field decays at a faster rate, coil placement
can be optimized to sense only the indirect coupling signal or remote
field signal.
Direct coupling pathDrive Coil Pickup Coil
Indirect coupling Path
Indirect coupling Path
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Indirect Coupling Path
Pickup UnitDrive Unit Direct Coupling Path
The probe blocks the direct coupling path. The energy released from
the drive unit is forced to go along the indirect coupling path.
Therefore, the entire signal received by the pickup unit has passed
the wall twice and carries the whole information about the wall
condition.
RFEC for General Applications
GRFEC TechniqueTo have the RFEC phenomenon to occur in objects of other geometries
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Typical GRFEC Probes (1)
Sliding Probes
RF2 V3A RF4 V5
Footprint: 0.85” x 2.15”Footprint: 0.30” x 0.62”
RF3 V2
Footprint: 0.675x 1.75”
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Ring #5
ID = 0.350”
OD = 0.910”
Ring #2
ID = 0.500”
OD = 1.250”
Typical GRFEC Probes (2)
Ring Probes
Ring #4
ID = 0.350”
OD = 1.100”
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Portable Instrument SSEC III
A modification
of conventional
EC instrument;
Capable of
working with
GRFEC probes
as well as
conventional
EC probes
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Corrosion Detection
1. Detection 0.040” corrosion thru a 0.6”+ multilayer Al stack
using sliding probe RF4
• Previously made C-scan image
• A-scan over a 0.040” deep corroded area
2. Detecting corrosion pits thru 0.200” aluminium layer using
RF4
3. Performances of other GRFEC sliding probes
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Example 1:5 Layer 2024 T3 Aluminum Specimen
0.1” + 0.1” + 0.19” +0.19” + 0.063”
Total Thickness = 0.643”
Corrosion on Bottom of 5th Layer
Location = 0.603”
3” 3” 0.040”
Rf4 V3
Location = 0.603”
0.5” 0.5” 0.040”
0.100”
0.100”
0.063”
0.190”
0.190”
C-scan images created in 2002
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Corrosion Standard – the 5th Layer
0.063” thick aluminum, chemical thinning on one side
0.5” 0.5” 0.040"
3.0” 3.0” 0.040"
Standard provided by CNDE, ISU
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Test Result - Example13” 3” 0.040” 5th Layer Bottom Side Corrosion, f=200Hz
Total Thickness = 0.643”, Location = 0.603”
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Test Result – Example20.5” 0.5” 0.040” 5th Layer Bottom Side Corrosion, f=200Hz
Total Thickness = 0.643”, Location = 0.603”
Part I – Deeply hidden corrosion detection
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Detection 0.040” corrosion thru a 0.6”+
multilayer Al stack using sliding probe RF4
4 Layer 2024 T3 Aluminum plate stack with total thickness of
0.690” is placed on top of a 0.063” thick corrosion standard
Corrosion on top of the 5th Layer
3” 3” 0.040”
Rf4 V5
Location = 0.690”
0.5” 0.5” 0.040”
0.063”
A-scan over a 0.040” deep corroded area
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
RF4 0.690” on top of 3”x3”x 0.040” Corrosion (5.8%)
@ f = 200Hz
Impedance Strip ChartX
Y
~270 mv
Y
~270 mv
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Detecting corrosion pits on back
side of a 0.200” aluminium layer
using RF4
GRFEC sliding probe can be
focused on a small spot
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Corrosion Pits Test Sample provide By Lockheed Martin
U1U2U3U4U5
L5 L4 L3 L2L1
U5U4U3U2U1
L1 L2 L3 L4 L5
Scanned Side
Corroded Side
24”
0.2
0”
U5U4U3U2U1
L1 L2 L3 L4 L5
.265×.141×.014 .228×.120×.012 .180×.160×.011 .170×.150×.014 .130×.130×.020
.265×.170×.018 .263×.200×.017 .210×.190×.021 .190×.180×.026 .150×.150×.041
Approximate dimensions of the corrosion pits
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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C-scan images made in April, 2008
@ 2kHz
@ 2kHz
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
Performances of other GRFEC
sliding probes
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
RF3 0.190” on top of 2”x2”x 0.006” corrosion (3.2%)
@ f = 800Hz
Impedance Strip ChartX
Y
~135mv
~135mv
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
RF2 0.100” on top of 1”x1”x 0.006” corrosion (6.0%)
@ f = 4.0kHz
Impedance Strip ChartX
Y
~1,100mv
~1,100mv
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Crack detection
Detecting lower layer EDM notches
through a up to 0.500” thick aluminium
upper layer structure
Using a GRFEC ring probe
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Example # 1 - C130 lower wing box
application:
Detecting 2nd layer EDM notches through 0.250”/0.500” thick
first aluminium layer
Front Side
1st lay 0.25” steel fasteners
Back Side
0.100”– 0.600” long EDM made in these holes
2nd layer aluminum strip 0.140” thick &1.0”wide
Standard #1 – 0.250” thick first layer
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
Mode 1 - Place probe on
top of each fastener
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00”
0.3
00
”
0.4
00
”
0.5
00
”
0.6
00
”
Y
Number of data acquisition points
C-130 Lower wing box standard with
2nd layer horizontal EDM notches
Mode 1 - Place probe on top of each fastener
~120mv
~750mv
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00
”
0.3
00
”
0.4
00
”
0.5
00
”
Y
Number of data acquisition points
C-130 Lower wing box standard with
2nd layer vertical EDM notches
Mode 1 - Place probe on top of each fastener
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00
”
0.3
00
”
0.4
00
”
0.5
00
”
Y
Number of data acquisition points
C-130 Lower wing box standard with
2nd layer vertical EDN notches
Mode 1 - Place probe on top of each fastener
~50mv~70mv
~280mv~380mv
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Standard #2 – 0.500” thick first layer
31
A1
A2
B1
B2
Top View
Bottom View
0.200” long EDM 0.200” long EDM
Flush-head steel fastener Raised-head steel fastener
Example # 1 - C130 lower wing box
application:
Detecting 2nd layer EDM notches through 0.250”/0.500” thick
first aluminium layer
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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Standard 2 - Detecting 0.200” EDM below a 0.500” thick Al
layer with steel flush head fastener on @ f = 100Hz
C-130 Lower wing box standard with
2nd layer horizontal EDN notches
Mode 1 - Place probe on top of each fastener
0.004v
0.004v
0.464v
0.464v 0.5” thick 1st layer flush head fastener
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
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C-130 Lower wing box standard with
2nd layer horizontal EDN notches
Mode 1 - Place probe on top of each fastener
Standard 2 - Detecting 0.200” EDM below a 0.500” thick Al
layer with steel raised head fastener on @ f = 100Hz
0.5” thick 1st layer Raised head Fastener
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
Mode 2 – Using a GRFEC
ring probe as a sliding
probe
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00
”
0.3
00
”
0.4
00
”
0.5
00
”
0.6
00
”
X
Y
Number of data acquisition points
No
ED
M No
ED
M
C-130 Lower wing box standard with
2nd layer horizontal EDM notchesMode 2 – Using a GRFEC probe as a sliding probe
@ f = 80Hz
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00
”
0.3
00
”
0.4
00
”
0.5
00
”
0.6
00
”
X
Y
Number of data acquisition points
No
ED
M
No
ED
M
C-130 Lower wing box standard with
2nd layer horizontal EDM notchesMode 2 – Using a GRFEC probe as a sliding probe
@ f = 80Hz Zoom-in
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00
”
0.3
00
”
0.4
00
”
0.5
00
”
Y
Number of data acquisition points
X @ f = 80Hz
C-130 Lower wing box standard with
2nd layer vertical EDM notchesMode 2 – Using a GRFEC probe as a sliding probe
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
No
ED
M
No
ED
M
0.1
00
”
0.2
00”
0.3
00
”
0.4
00
”
0.5
00
”
Y
Number of data acquisition points
X
C-130 Lower wing box standard with
2nd layer vertical EDM notchesMode 2 – Using a GRFEC probe as a sliding probe
@ f = 80Hz Zoom-in
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
39
Summary
SSEC III + GRFEC technique is
capable of detecting deeply hidden
corrosion and cracks.
Potentially it could be a powerful tool
to add new functions to MAUS
Presentation at 2011 MAUS User Group Meeting , 13 September, 2011 Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.Innovative Materials Testing Technologies, Inc.
40
Thanks and
please questions