A novel Non-Destructive Inspection (NDI) method for improved defect detection in composites and traditional materials
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Technology abstract
Theta Technologies, a UK SME, has developed a novel NDI technique that can detect early stage defects (kissing bonds, cracks, and delaminations) in traditional materials and composites. Such defects reduce the strength and fatigue life of components and – crucially – are not readily detectable by traditional NDI. This game-changing technology can reduce waste and provide greater reliability by ensuring that materials and products are safe, compliant, and fit-for-purpose.
Technology Description
Non-destructive inspection (NDI) allows users to ‘see’ inside a material or component in order to check for defects. NDI is standard practice for many industrial sectors (such as aerospace manufacture) where verifying the integrity of safety-critical, complex, and high-value components is essential. However, conventional NDI techniques suffer limitations that prevent their application in certain areas.
Theta Technologies, a UK SME that specialises in ultrasonic NDI, has developed novel NDI capability that can find early stage defects with unprecedented detection sensitivity. The non-linear acoustic NDI methods can detect defects such as micro-cracks (of the order of 100um x 1um), kissing bonds (where two surfaces are in intimate contact but have greatly reduced bond strength), and delamination, in a wide range of materials including metals, alloys, and composites.
As well as traditional ultrasonic NDI applications (e.g. aerospace manufacture, rail inspection, offshore oil & gas), the novel methods have been successfully applied to kissing bond detection in Friction Stir Weld (FSW) parts. This is a major area of application as FSW is used for many industries including shipbuilding, automotive manufacture, robotics, and space craft component manufacture.
Innovations & Advantages
- Ability to detect early stage defects including micro-cracks, delaminations, and kissing bonds
- Multi-mode use
- Earlier warning of degradation than is achievable with conventional NDI
- Applicable to wide range of materials including composites (PMCs and CMCs) and traditional materials (alloys and metals)
- Applicable to welds, coatings, sandwich constructions, and granular materials
- Bespoke Turnkey System including installation, commission, onsite training, and a maintenance and support programme
Current and Potential Domains of Application
The multi-mode NDI instrument was originally developed to detect early stage defects in a range of materials, including:
- Alloys and metals
- Welds
- PMCs (polymer matrix composites)
- CMCs (ceramic matrix composites)
- Coatings
- Granular materials
- Sandwich constructions
Ultrasonic NDI is widely used for industrial sectors including:
- Offshore oil (pipe quality checks)
- Aerospace (component verification)
- Defence
- Marine
- Transport (rail inspection)
For detection of kissing bonds in Friction Stir Weld (FSW) parts, which are widely used for:
- Automotive manufacture
- Rail car manufacture
- Fabrication (pressure vessels, vacuum vessels, façade panels)
- Heat exchanger production
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Thetagram: a ‘heat map’ of non-linearities in a Friction Stir Weld