Inspection of Water Ingress in Honeycomb Core Material

Water ingress in honeycomb core material is a critical issue in aerospace, automotive, and construction industries as it can compromise structural integrity and lead to significant damage over time. Traditional inspection methods, such as visual inspection and ultrasonic testing, have limitations in detecting and characterizing water ingress.

This article explores the application of active thermography, specifically flash thermography and transient thermography, as an effective non-destructive testing (NDT) technique for identifying water ingress in both non-metallic and metallic honeycomb cores. Additionally, we will discuss the advantages of using infrared NDT over ultrasonic testing for this specific application.

Active Thermography for Water Ingress Detection

Flash Thermography

Flash thermography is a widely used active thermography technique that involves subjecting the honeycomb structure to a short-duration, high-energy pulse of heat (e.g., using a flash lamp). As water has different thermal properties compared to the honeycomb material, any water present in the core will affect the way heat is transferred during the inspection process. A high-speed infrared camera captures the surface temperature response, revealing thermal anomalies indicative of water ingress.

Transient Thermography

Transient thermography relies on a continuous heating source, such as an infrared heater or a moving hot air stream, to induce a thermal gradient across the honeycomb structure. Similar to flash thermography, a thermal camera captures the surface temperature response. By analyzing the temperature decay over time, areas with water ingress can be detected and characterized.

Water Ingress Detection in Non-Metallic Honeycomb Cores

Non-metallic honeycomb cores, often composed of materials like aramid fibers or polymers, pose unique challenges for water ingress detection. The presence of water can lead to swelling, delamination, or loss of mechanical properties. Active thermography techniques provide several advantages in this context:

Sensitivity to Water Content

Active thermography can detect even small amounts of water content within non-metallic honeycomb cores. By analyzing the surface temperature response, thermographic images can highlight areas with moisture accumulation, enabling early detection of water ingress and facilitating preventive maintenance.

Enhanced Depth Resolution

Active thermography techniques can provide depth information regarding the location of water ingress. By analyzing the thermal response over time or applying advanced image processing algorithms, it is possible to estimate the depth of water infiltration, aiding in assessing the severity of the damage.

Water Ingress Detection in Metallic Honeycomb Cores

Metallic honeycomb cores, typically composed of materials like aluminum or stainless steel, have different thermal properties compared to non-metallic cores. However, active thermography remains effective for water ingress detection in metallic honeycomb cores, with a few considerations:

Thermal Conductivity Differences

Metallic honeycomb cores have higher thermal conductivities than non-metallic ones. This can result in faster heat transfer during active thermography, potentially affecting the detection sensitivity. Adjustments in the heating and inspection parameters may be required to optimize the water ingress detection process for metallic honeycomb cores.

Subsurface Reflections

Metallic honeycomb cores can produce reflections of thermal energy due to their metallic nature. These reflections can interfere with the detection of water ingress anomalies. Proper image processing techniques, such as advanced filtering algorithms, can be applied to mitigate the impact of these reflections and enhance the detection accuracy.

Advantages of Infrared NDT for Detection of Water Ingress over Ultrasonic Testing

Impact damage and fluid ingress.

Surface Accessibility

Ultrasonic testing requires direct contact between the transducer and the surface being inspected. In contrast, infrared NDT is a non-contact technique, allowing inspections to be performed without physically touching the honeycomb structure.

Rapid Inspection

Infrared NDT techniques, such as flash thermography and transient thermography, offer rapid inspection capabilities. The application of short-duration heat pulses or continuous heating sources enables quick scanning of large areas. This is particularly advantageous when inspecting honeycomb structures with complex geometries or when time is a critical factor.

Full-Field Inspection

Infrared NDT provides full-field inspection capabilities, allowing the entire surface of the honeycomb structure to be examined simultaneously. This is in contrast to ultrasonic testing, which typically requires scanning point-by-point, resulting in a time-consuming process. With infrared NDT, potential water ingress areas can be quickly identified, localized, and characterized, enabling efficient decision-making regarding maintenance or repair.

Detection Sensitivity

Active thermography techniques have shown excellent sensitivity to small defects and moisture content variations. The detection of water ingress anomalies, even at early stages, is achievable using high-resolution infrared cameras and appropriate heating methods. Ultrasonic testing, on the other hand, may have limitations in detecting certain types of defects or variations in moisture content.

Thermal result image with fluid ingress indication.

Non-Destructive

Infrared NDT is a non-destructive technique that does not alter or damage the honeycomb structure during inspection. This is particularly important for critical applications where the structural integrity of the honeycomb core must be preserved. Ultrasonic testing, while also non-destructive, requires the use of couplant and direct contact with the surface, which can be challenging or impractical in certain scenarios.

Cost-Effectiveness

Infrared NDT techniques offer cost-effective inspection solutions. The equipment required for active thermography, including infrared cameras and heat sources, is becoming more affordable and accessible. Additionally, the rapid inspection capabilities of infrared NDT can reduce labor costs and minimize production downtime, making it a viable option for industries that require efficient and cost-effective inspection processes.

Conclusion

Active thermography techniques, such as flash thermography and transient thermography, provide effective solutions for detecting water ingress in both non-metallic and metallic honeycomb cores. With their sensitivity, depth resolution, and rapid inspection capabilities, active thermography techniques offer advantages over traditional ultrasonic testing methods. Infrared NDT allows for non-contact, full-field inspection, enabling the detection of water ingress anomalies at early stages and facilitating timely maintenance or repair actions. As technology continues to advance, infrared NDT is poised to play an increasingly significant role in ensuring the structural integrity and performance of honeycomb core-based structures in various industries.

Challenges with Traditional Inspection Methods

Limitations of Dye Penetrant Testing

Large turbine blade with ultrasonic horn in test fixture.

Dye penetrant testing, a commonly used method for crack detection, primarily focuses on surface-breaking cracks. However, it has inherent limitations when it comes to detecting subsurface cracks in turbine blades. The nature of subsurface cracks makes it challenging for liquid penetrants to reach the crack depths, resulting in limited or no indication of their presence. Additionally, visual examination is often insufficient for identifying subsurface cracks, especially when they are located deep within the material.

Insufficient Crack Visualization

Surface examinations alone may not provide an accurate representation of the extent and severity of turbine blade cracks. Without clear visualization, it becomes challenging to characterize cracks in terms of size, depth, and extent, hindering effective maintenance and repair decisions.

Vibro-Thermography for Turbine Blade Inspection

To overcome the limitations of traditional inspection methods, advanced techniques like vibro-thermography have emerged as promising solutions for more comprehensive turbine blade inspections.

How Vibro-Thermography Works

Thermal result image with large crack indication on bottom edge of blade.

Vibro-thermography combines the principles of vibration excitation and thermal imaging to detect cracks in turbine blades. The technique involves inducing mechanical vibrations into the blade and monitoring the surface temperature response using an infrared camera. By analyzing the thermal patterns, it is possible to identify both surface and subsurface cracks.

Vibration Excitation

Vibro-thermography utilizes various methods to induce vibrations in turbine blades. These include mechanical excitation using shakers, air-coupled excitation, or piezoelectric actuators. The vibrations cause dynamic stress redistribution, leading to localized heating at crack sites. This phenomenon enables the detection of subsurface cracks that may not be visible to the naked eye.

Thermal Imaging

An infrared camera captures the surface temperature response of the turbine blade during vibration excitation. Subsurface cracks disrupt heat flow, resulting in thermal anomalies that can be visualized and analyzed. Advanced image processing techniques can enhance crack visibility and aid in quantitative characterization, providing valuable insights for maintenance and repair decisions.

Advantages of Vibro-Thermography for Turbine Blade Inspection

Subsurface Crack Detection

Vibro-thermography excels in detecting subsurface cracks in turbine blades. By inducing vibrations and monitoring the resulting thermal patterns, the technique can identify cracks even when they are not visible on the surface. This capability enables comprehensive inspection, ensuring the integrity of turbine blades, even in critical areas prone to subsurface cracking.

Enhanced Crack Visualization

Thermal results image – front view of turbine blade with crack indications.

The thermal imaging component of vibro-thermography provides a visual representation of cracks, making them easier to identify and characterize. The contrast between crack-induced thermal anomalies and the surrounding material facilitates accurate detection and quantification of crack size, depth, and extent. This information allows maintenance teams to make informed decisions regarding repairs or replacements.

Non-Destructive Testing

Vibro-thermography is a non-destructive testing technique that does not alter or damage the turbine blade during inspection. The vibrations applied are controlled and within safe limits, allowing for repeated inspections without compromising the structural integrity of the blade. This advantage is particularly significant in critical applications where turbine blade performance is crucial.

Turbine blade rear view with sub-surface micro-cracking indications.

Time-Efficient Inspection

Vibro-thermography offers a time-efficient inspection process, allowing for rapid scanning of turbine blades. The application of controlled vibrations and the real-time monitoring of thermal responses enable quick assessment of the blade’s condition. This time-saving advantage is particularly valuable in industries where minimizing downtime is essential.

Emerging Trends in Vibro-Thermography

As technology continues to advance, new trends and developments are emerging in the field of vibro-thermography, enhancing its capabilities and expanding its applications. Here are some notable trends to watch out for:

Multi-Frequency Excitation

Traditional vibro-thermography techniques rely on single-frequency excitation to induce vibrations in turbine blades. However, researchers are exploring the benefits of multi-frequency excitation, where multiple vibration frequencies are applied simultaneously. This approach can provide more detailed information about the structural integrity of the blades, improving crack detection accuracy and reducing false positives.

Integration of Artificial Intelligence

The integration of artificial intelligence (AI) techniques with vibro-thermography is gaining traction. AI algorithms can analyze the thermal response data collected during inspections, enabling automated crack detection and characterization. Machine learning algorithms can learn from past inspection data to improve the accuracy and efficiency of future inspections, making the process even more reliable and cost-effective.

Real-Time Monitoring

Real-time monitoring during vibro-thermography inspections is becoming increasingly important. By continuously monitoring the thermal response of turbine blades as vibrations are applied, potential defects or changes in crack behavior can be identified promptly. Real-time monitoring enables proactive maintenance and repair decisions, minimizing the risk of unexpected failures and maximizing the lifespan of turbine blades.

Portable and Handheld Systems

With advancements in sensor technology and miniaturization, portable and handheld vibro-thermography systems are becoming more accessible. These compact systems allow for on-site inspections and can be easily transported to different locations. Portable systems offer convenience and flexibility, particularly in situations where transporting large equipment is challenging or time-consuming.

Interested in Implementing Vibro-Thermography for Your Inspections?

If you’re looking to optimize your inspection processes and enhance the reliability of crack detection in turbine blades or other critical components, we can help. MoviTHERM offers state-of-the-art vibro-thermography systems that can revolutionize your inspection capabilities.

Our experienced team can assess your specific needs and provide tailored solutions to meet your requirements. Whether you operate in the aerospace, power generation, or industrial sector, vibro-thermography can offer significant advantages in ensuring the integrity and safety of your parts.

Contact us today to schedule a consultation and find out how our systems can help you detect and characterize cracks in your turbine blades or other critical components.

Transient Thermography for Bond Line Inspection

Transient thermography, a dynamic infrared NDT technique, involves applying a localized heat pulse to the surface of the CFRP structure and monitoring the resulting temperature changes using an infrared camera. The recorded thermal response provides valuable information about the bond line integrity and delamination within the stringer.

Heat Pulse Excitation

A controlled heat pulse is applied to the surface of the CFRP stringer. This excitation generates a thermal gradient, causing heat to flow through the structure and interact with the bond lines. Areas with anomalies, such as poor bonding or delamination, disrupt the heat flow and result in distinct thermal patterns.

Thermal Imaging and Analysis

An infrared camera captures the surface temperature response during and after the heat pulse. The thermal images are analyzed to identify variations in heat dissipation, indicating potential defects in the bond lines. Advanced image processing techniques, such as time-temperature curve analysis or phase-based thermographic analysis, can be employed to enhance defect visibility and accurately assess bond line conditions.

Measuring Bond Strength

Transient thermography offers the capability to measure bond strength in CFRP stringers by assessing the thermal characteristics of the bond lines. Measuring bond strength is essential for evaluating the structural integrity and reliability of composite materials. By analyzing the thermal response and employing advanced testing methods, several factors can be considered to accurately assess bond strength.

Photo of CFRP panel with partially delaminated stringers.

Thermal Conductivity Differences

The bond line area exhibits different thermal conductivity compared to the surrounding CFRP material. This discrepancy in thermal properties affects heat transfer during transient thermography. By carefully analyzing the thermal response, including temperature profiles and thermal gradients, it is possible to estimate the bond strength based on the bond line’s ability to transmit heat. Understanding the relationship between thermal behavior and bond strength provides valuable insights into the quality and effectiveness of the bonding process.

Quantitative Assessment

To determine bond strength, quantitative analysis of the thermal response is crucial. By comparing the temperature profiles and gradients in regions with known bonding conditions, a correlation can be established between thermal behavior and bond strength. This correlation can be further refined through calibration using reference samples with known bond strengths. Through this quantitative assessment, it becomes possible to assign numerical values to bond strength, enabling a more precise evaluation of the structural integrity of CFRP stringers.

Influence of Manufacturing Variables

It is important to consider various manufacturing variables that can impact bond strength. Factors such as surface preparation, adhesive type, curing conditions, and application techniques play a significant role in determining the strength of the bond line. By understanding the influence of these variables on the thermal response, it becomes possible to assess the bond strength accurately. This knowledge also allows for optimization of the manufacturing process to ensure consistent and robust bonding in CFRP structures.

Long-Term Bond Performance

Transient thermography not only enables the measurement of bond strength during initial inspection but can also provide insights into the long-term performance of the bond line. Over time, environmental conditions, cyclic loading, and other factors can affect the bond strength. By periodically conducting transient thermography inspections, changes in the thermal response can be monitored, allowing for early detection of potential degradation or delamination. This proactive approach helps to ensure the ongoing structural integrity of CFRP stringers and facilitates timely maintenance or repair actions.

Detecting Delaminated Areas

Transient result image showing bond line and partial delamination.

Transient thermography is highly effective in detecting delaminated areas within CFRP stringers. Delamination refers to the separation of layers within the composite structure, compromising its strength and integrity. Key considerations for delamination detection include:

Heat Flow Disruption

Delamination disrupts the normal heat flow within the CFRP structure, resulting in distinct thermal anomalies. During transient thermography, the presence of delamination manifests as areas with slower heat dissipation or abnormal thermal gradients. These thermal patterns are easily detectable in the captured infrared images.

Depth Assessment

Transient thermography can provide valuable information about the depth and extent of delamination. By analyzing the thermal response over time and employing advanced image processing algorithms, the depth of the delaminated region can be estimated. This information helps in assessing the severity of the defect and determining appropriate repair or maintenance actions.

Advantages of Transient Thermography for CFRP Stringer Inspection

Transient thermography offers a range of advantages when it comes to inspecting bond lines and detecting delaminated areas in CFRP stringers. These advantages make it a valuable tool for ensuring the structural reliability of CFRP structures across various industries. Let’s explore some of the key benefits of using transient thermography:

Non-Destructive and Non-Contact Inspection

One of the primary advantages of transient thermography is its non-destructive and non-contact nature. It allows for the assessment of CFRP stringers without causing any damage to the structure. This means that inspections can be repeated multiple times without compromising the integrity of the component. Non-destructive and non-contact inspection methods are essential for ensuring the longevity and usability of CFRP structures.

Rapid Inspection

Transient thermography offers rapid inspection capabilities, enabling the scanning of large areas in a relatively short amount of time. The application of controlled heat pulses and real-time thermal imaging allows for efficient detection and characterization of bond line defects and delaminated areas. This speed and efficiency are particularly advantageous when inspecting large structures or when time is a critical factor, minimizing production or maintenance downtime.

Full-Field Inspection

Infrared NDT techniques, such as transient thermography, provide full-field inspection capabilities. The entire surface of the CFRP stringer can be examined simultaneously, providing comprehensive information about the bond lines and delamination across the structure. This advantage minimizes the risk of missing critical defects and ensures thorough inspection coverage. Full-field inspection is particularly beneficial for identifying localized anomalies or irregularities that may not be apparent through other inspection methods.

High Sensitivity to Defects

Transient thermography exhibits high sensitivity to defects, including delamination and bond line irregularities. The thermal imaging technique can capture even subtle variations in heat dissipation, enabling the detection of hidden or sub-surface defects that may not be visible to the naked eye. This sensitivity ensures that potential issues are identified early, allowing for timely repairs or interventions to prevent further damage or structural failures.

Versatility and Adaptability

Transient thermography is a versatile inspection method that can be applied to various types of CFRP structures and configurations. It can be used for both flat and curved surfaces, making it suitable for a wide range of applications. The technique can also be adapted to different inspection scenarios and can be combined with other non-destructive testing methods to provide a more comprehensive assessment of the CFRP stringers.

Conclusion

Transient thermography offers a reliable and efficient method for inspecting bond lines and detecting delaminated areas in CFRP stringers. By utilizing heat pulse excitation and analyzing the resulting thermal response, this infrared NDT technique provides valuable insights into bond line integrity and the presence of delamination. The ability to measure bond strength and assess delamination depth, along with its non-destructive and rapid inspection capabilities, makes transient thermography a valuable tool for ensuring the structural reliability of CFRP stringers in various industries.

Battery Testing During the Development Process Using Infrared

As battery technology advances at a rapid pace, the demand for high-performance and reliable energy storage solutions continues to rise. To meet these demands, battery manufacturers face the challenge of ensuring optimal quality during the development and production phases. One of the most effective ways to test batteries and identify potential flaws or defects is through active thermography.

This innovative technique harnesses the power of thermal imaging to uncover hidden problems, improve battery performance, and enhance overall quality assurance. In this article, we will delve into the world of active thermography and explore how it is revolutionizing battery testing during development and production.

What is Active Thermography?

Active thermography is a non-destructive testing method that utilizes thermal imaging to detect and analyze variations in temperature within an object or material. It involves subjecting the battery to an external energy source, typically a short burst of heat or light, and then capturing the resulting temperature distribution using an infrared camera. By analyzing the thermal patterns, engineers can identify defects such as delamination, internal short circuits, electrode malformation, and thermal hotspots, among others.

The Benefits of Active Thermography in Battery Testing

1. Early Detection of Defects

Active thermography allows for the early detection of hidden defects that might be otherwise undetectable by conventional testing methods. This enables manufacturers to address issues at an early stage, reducing costs associated with faulty battery production.

2. Non-Destructive Testing

Unlike destructive testing methods that require disassembling batteries, active thermography is non-destructive. It does not damage the battery, making it an ideal technique for testing large quantities of batteries during production without compromising their integrity.

3. Quick and Efficient

Active thermography provides rapid results, allowing for high throughput during battery testing. It enables manufacturers to streamline their quality control processes and identify defective units promptly, thereby reducing production time and costs.

4. High Sensitivity

The thermal imaging technology used in active thermography is highly sensitive, capable of detecting even subtle temperature variations. This makes it ideal for identifying internal defects and ensuring the overall quality and reliability of batteries.

5. Versatility

Active thermography can be applied to various battery chemistries, including lithium-ion, nickel-metal hydride, and lead-acid batteries, among others. This versatility makes it an invaluable tool for battery manufacturers across different sectors.

Implementing Active Thermography in Battery Testing

To implement active thermography effectively, battery manufacturers follow a systematic approach:

Thermal Camera Setup

A high-resolution infrared camera is used to capture the thermal patterns of the battery. The camera is positioned to capture the entire battery surface and has the capability to measure temperature variations accurately.

Thermal Excitation

A controlled heat source or light pulse is applied to the battery, causing localized temperature variations. This excitation is carefully designed to stress the battery without causing any damage.

Thermal Image Acquisition

The infrared camera records the temperature distribution on the battery’s surface in real-time during the excitation phase. The resulting thermal images provide valuable insights into the battery’s internal structure and potential defects.

Image Analysis and Defect Detection

Advanced image processing algorithms are employed to analyze the thermal images and identify irregularities. These algorithms can automatically detect defects such as delamination, internal shorts, and thermal hotspots, allowing for efficient defect classification and identification.

Quality Control and Feedback Loop

The defects identified through active thermography are logged and used to refine the manufacturing process. This information helps manufacturers improve their battery design, production techniques, and overall quality control measures.

Active thermography for battery testing holds immense potential for a wide range of industries, enabling enhanced quality control, improved performance, and increased safety. Here are several industries that can benefit from the application of active thermography:

Electric Vehicles (EVs)

The electric vehicle industry heavily relies on battery technology, making active thermography a valuable tool for EV manufacturers. By utilizing active thermography, they can detect internal defects, identify thermal hotspots, and ensure the overall integrity of battery packs. This helps optimize battery performance, extend driving range, and enhance safety for electric vehicles.

Consumer Electronics: From smartphones and tablets to laptops and wearable devices, active thermography can benefit the consumer electronics industry. Manufacturers can use this technique to assess battery quality, identify potential issues like cell deformation or thermal abnormalities, and improve the performance and reliability of battery-powered consumer electronics.

Renewable Energy

Active thermography is applicable to energy storage systems used in renewable energy applications, such as solar and wind. By employing this technique, manufacturers can assess the performance and health of batteries integrated into energy storage systems. This ensures optimal energy management, improves system efficiency, and supports the stability and reliability of renewable energy generation.

Aerospace and Defense

The aerospace and defense industries rely on batteries for various applications, including aircraft systems, satellites, drones, and military equipment. Active thermography enables thorough battery testing, allowing manufacturers to detect internal defects, monitor thermal behavior, and ensure the reliability and safety of batteries in critical aerospace and defense applications.

Medical Devices

Medical devices often utilize batteries for portability and functionality. Active thermography can be instrumental in testing and validating the batteries used in medical devices, ensuring optimal performance and safety. By detecting potential issues early on, manufacturers can deliver reliable and efficient battery-powered medical devices.

Energy Storage Systems

Beyond renewable energy applications, active thermography is crucial for energy storage systems used in grid-scale energy storage or backup power systems. This technique assists in identifying defects, thermal hotspots, or aging effects within the batteries, enabling operators to optimize the performance, reliability, and longevity of energy storage systems.

Industrial Equipment and Machinery

Industries such as manufacturing, logistics, and construction rely on batteries for powering industrial equipment and machinery. Active thermography allows manufacturers to identify potential battery issues, monitor thermal behavior, and ensure the overall performance and safety of battery-powered equipment in demanding industrial environments.

At MoviTHERM, we understand that each industry and application has unique requirements and challenges. We recognize that some companies may be unsure if active thermography is the right solution for their specific battery testing needs. That’s why we offer feasibility studies as part of our comprehensive services. Our experienced team works closely with clients to assess their requirements, evaluate the feasibility of active thermography for their application, and determine the potential benefits and limitations.

Our feasibility studies serve as a valuable tool in determining the viability and effectiveness of active thermography, enabling companies to optimize their quality control methods and achieve superior results. With MoviTHERM, you can have confidence in exploring the potential of active thermography for your battery testing needs, backed by our expertise and commitment to delivering tailored solutions.