N092-097 TITLE: Automated, Rapid Non-Destructive Inspection (NDI) of Large Scale Composite Structures

TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-261, CH-53K, Heavy Lift Helicopter Program

OBJECTIVE: Develop an automated NDI capability for the rapid and accurate inspection of the composite structures of aircraft, such as trailing edges, flight control surfaces, and fuselage, during depot maintenance.

DESCRIPTION: There is a need to develop an automated NDI capability for the rapid and accurate inspection of large composite aircraft structure during depot maintenance. Such a development should enhance the readiness of Naval aircraft by minimizing the time a vehicle spends in the depot and by reducing the possibility that the aircraft will suffer an unexpected failure during operation by ensuring the structural integrity of the structure. Current NDI procedures and equipment are designed to inspect small areas for defects and have limited resolution, which result in excessive time spent inspecting large areas or the missing of critical defects completely. Rapid inspection of large areas of the aircraft using current procedures is not feasible.

An automated non-destructive inspection (NDI) system with the capability to rapidly inspect large areas of composite structures and automatically identify relatively small defects is sought. Successful development should result in decreased maintenance downtime, increased throughput, cost savings, and increased structural integrity of aircraft.

Proposed solutions should include an automated inspection system and an intelligent defect identification tool to pinpoint the exact location and nature of defects found. The NDI system will need to find voids, delaminations, and disbonds of .25 square inches and/or 1.0 inch length 90% of the time with a 95% probability. Defects identified could then be inspected in more detail using existing procedures.

An example of the size and type of composite structure to be scanned is the KC-130J wing trailing edges, which extend linearly almost 57 feet and measure about 5 feet at its widest point. The trailing edge panels are made of carbon-epoxy composite material, with a layer of embedded copper mesh for lightning protection, and are fastened onto the aluminum substructure with Monel rivets. The goal is to field a system that could autonomously inspect a structure such as described here in no more than one work week (2 shifts) with minimal involvement from the NDI technicians after initial setup.

PHASE I: Develop a conceptual design of the inspection method and demonstrate feasibility of the proposed solution to accurately and rapidly detect defects on large composite aircraft structures in-situ. Provide an estimate of the time that the inspection is expected to take and the size of the defects that are expected to be found.

PHASE II: Complete the design of the inspection method and develop the prototype NDI system. Demonstrate its capability to meet the requirements laid out above on NDI standards and on an aircraft undergoing depot maintenance.

PHASE III: Develop the prototype into a commercially viable NDI method, which will then be used by the depot(s) performing aircraft maintenance and will be marketed to commercial maintenance, repair, and overhaul (MRO) facilities for use on military and commercial aircraft.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Newly designed commercial aircraft such as the B-787 and A-380 make extensive use of composite materials that could be inspected using this capability. The MRO industry would benefit by having a rapid, accurate NDI capability for composite materials, which would decrease the aircraft work days and increase the accuracy of their inspections. The system could also be adapted for use in inspecting non-metallic boat hulls and large composite beams used in construction.

REFERENCES:
1. Implementing New NDI Procedures on US Department of Navy C-130 Aircraft; Raymond Waldbusser, C-130 Fleet Support Team/NAVAIR, Eric Lindgren, Nondestructive Evaluation Branch/AFRL; 2008 Aging Aircraft Conference proceedings.

2. Probability of Detection Results and Deployment of the Inspection of the Vertical Leg of the C-130 Center Wing Beam/Spar Cap; Eric Lindgren, John Mandeville, Michael Concordia, Tim MacInnis, Jim Abel, John Aldrin, Floyd Spencer, Darren Fritz, Peter Christiansen, Tommy Mullis, and Ray Waldbusser; 2004 Aging Aircraft Conference proceedings.

KEYWORDS: Non Destructive Inspection (NDI); Composites; Rapid; Accurate; Automated; Depot Maintenance

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