N093-174 TITLE: Nondestructive Detection of Fiber Waviness in Laminates

TECHNOLOGY AREAS: Materials/Processes, Sensors, Electronics

ACQUISITION PROGRAM: Joint Strike Fighter (ACAT I); H-53 Heavy Lift Helicopter Program

OBJECTIVE: Develop a nondestructive inspection technique capable of detecting and characterizing fiber waviness/marcelling in graphite/epoxy and fiberglass/epoxy laminate materials.

DESCRIPTION: Fiber waviness in laminate materials can result from various aspects of the manufacturing process. Since fiber waviness or marcelling reduces structural strength, its detection and characterization is of importance to the Navy. Having a means of detecting and quantifying fiber waviness would significantly improve the quality control process of thick laminate parts subject to defects of this kind. While traditional ultrasonic and radiographic techniques have been used in the past, they are not reliable for more complex geometries. For this reason, an affordable nondestructive tool is desired to reliably detect, measure, and characterize fiber waviness in laminate materials. The primary materials of focus are graphite/epoxy and fiberglass/epoxy laminates of various geometries and up to 0.75 inch thick. Detection of fiber waviness throughout the thickness of the part is required. Consideration also needs to be given to other materials or obstructions that may exist between layers in a part. Composite fiber waviness must be detectable in and around molded-in metal sections of the component under inspection.

PHASE I: Develop and demonstrate an innovative technology that detects and measures in-plane and out-of-plane fiber waviness in graphite/epoxy and fiberglass/epoxy laminate materials. Manufacture or procure necessary laminate samples for feasibility demonstration.

PHASE II: Develop, construct and demonstrate a prototype for characterization testing and evaluation, capable of detecting and quantifying fiber waviness. Demonstrations should be performed using samples that are manufactured or procured and that are representative of what can be expected in the Fleet.

PHASE III: Implement full-scale production of the nondestructive evaluation (NDE) devices in quantities proportional to market and Navy demand.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Quality control process improvements from this technology would be applicable to any industry that is using composite material construction; i.e.; automotive, wind turbines, ship building, and commercial aircraft. Additionally, this technology may be developed into a low-cost replacement for medical computer tomography.

REFERENCES:
1. Ng, S. J. and Vizzini, A., "Mechanism of Marcel Formation in Thick Tapered Composites," 34th ISTC, Baltimore, MD, November 4-7, 2002.

2. B.B. Djordjevic, Henrique Reis, editors, G. Birnbaum, B. A. Auld, Technical editors, "Sensors for Materials Characterization, Processing, and Manufacturing," ASNT Topics on NDE, Vol. 1, published by ASNT, Columbus OH,1998.

3. D. Cerniglia, K. Y. Jhang, and B. B. Djordjevic "Non-Contact Ultrasonic Testing of Aircraft Lap Joints," 15th World Conference on NDT, Rome, Italy, Editor AIPnD, NDT.net October 2000.

KEYWORDS: Fiber Waviness; Fiber Distortion; Fiber Wash; Marcelling; Nondestructive Inspection; Nondestructive Testing

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