We describe Sonic Infrared Imaging NDE for materials and structures. In this imaging technique, a short ultrasonic pulse is applied to the structure/material to cause heating of the defects, while an infrared camera images the time evolution of the heating effect to identify the defective areas in the target. The heating effect is astonishing. In this paper, we'll include our study of Sonic IR imaging NDE on aircraft structure specimens, automotive specimens, etc. for metals, composites, ceramics, addressing fatigue cracks, and delaminations/disbonds. Some fundamental issues related to Sonic IR imaging NDE are discussed in this paper as well.
A novel nondestructive imaging technique, thermosonics, which combines ultrasonic/sonic excitation and advanced infrared imaging, will be described. In this paper, the authors will illuminate the physical principles underlining this technique, and demonstrate its applications to detection of cracks in teeth.
We describe a new technique, Thermosonics, that can be used to detect cracks in teeth. This technique was initially invented and developed for finding cracks in industrial and aerospace applications. The thermosonics technique employs a single short pulse (typically tens of milliseconds) of ultrasound excitation combined with infrared imaging. Ultrasonic waves vibrate the target material. This vibration causes rubbing and clapping between faying surfaces of any cracks which are present, resulting in a temperature rise around the cracks. An infrared camera is used to image the temperature distribution during and after the ultrasound excitation. Thus, cracks in teeth can be detected. Although this technique is still under development, it shows promise for clinical use by dentists.
We describe progress in thermosonic crack detection. In this technique, a short single pulse of ultrasound is used to cause cracks to heat up and become visible in the infrared. A low frequency (say 10's of kHz) ultrasonic transducer infuses the sample with sound. Where cracks, disbonds, delaminations or other defects are present, the sound field causes the defect to heat locally. The technique is applicable to large and irregularly shaped objects. We present illustrative applications of this technology to aerospace, and automotive inspections.
We describe a new hybrid ultrasonic/infrared technology in which ha short single pulse of ultrasound is used to cause cracks to heat up and become visible in the infrared. A low frequency (say 10's of kHz) ultrasonic transducer infuses the sample with sound. Where cracks, disbonds, delaminations or other defects are present, the sound field causes the defect to heat locally. The technique is applicable to large and irregularly shaped objects. We present a variety of images to show the capability for this technique to image cracks and other defects in metals as well as other materials. Both surface-interrupting and subsurface cracks are imaged. The technique can utilize hand-held ultrasonic sources, is insensitive to the position of the source on the sample, and yields wide-area images, with the defects showing as bright (higher temperature) regions against a dark (lower temperature) background. It can be used for inspection of relatively inaccessible complex part geometries.
We describe fast infrared imaging of both static and dynamic crush tests on glass-fiber composite tubes. The results are compared with video images of the same tests.
The state-of-the-art of Thermal Wave Imaging as an NDE technique for Aging Aircraft is summarized. The technique is described, and examples are given of application to the thermal wave inspection of aircraft for such subsurface defects as corrosion, disbonded doublers, fluid intrusion, and delaminations of composite structures.
The principles of thermal wave imaging for NDE are described. The technique utilizes high-power photographic flash lamps for pulse-heating of the surface of the composite. The cooling of the surface is monitored by means of an IR video camera. Disbonds, delaminations, and inclusions are seen in the resultant thermal wave images, with deeper features appearing systematically at later times. Examples of the application of thermal wave imaging to nondestructive evaluation of boron fiber composite reinforcement patches, and graphite-fiber aerospace composite materials are described.
We describe a pulsed method for measuring the principal values of the thermal diffusivity tensor of an anistropic materials. The technique utilizes IR imaging of a shadow as a function of time and space.
We describe a high-frequency IR lock-in imaging technique which relies on the use of an externally synchronized, snapshot-mode, infrared focal plane array camera.
We describe the application of IR thermal wave imaging for the nondestructive evaluation of composites and coatings. The technique uses pulsed surface heating and fast, synchronous IR imaging of the surface temperature to form images of subsurface defects in materials. In the case of composites and coatings, we present examples of the detection of defects such as delaminations, disbonds, subsurface impact damage, fluid infiltration, etc. The technique can be used to measure the depths of defects, and also the thicknesses of various coatings.
We describe an IR thermal wave imaging technique for making corrosion thinning determinations on aging aircraft skins. The technique uses pulsed surface heating and fast, synchronous IR imaging of subsurface structure, such as skin corrosion and disbonded doublers or tear straps. Sensitivity to corrosion thinning of less than two percent is demonstrated. Practical implementation of a simplified numerical measurement algorithm is presented, and the results are compared with profilometry and ultrasonic measurements of calibration standards. Examples are presented of thermal wave imaging of fuselage skin corrosion of a B737 testbed aircraft in a hangar environment at the FAA's Aging Aircraft NDI Validation Center.
We describe a thermal wave technique for making defect depth determinations. Both theory and experiment are presented, and the results are compared. Examples of defects having different lateral dimensions and boundary conditions are given.
Photothermal techniques are widely used for measuring optical absorption of thin film coatings. In these applications the calibration of photothermal signal is typically based on the assumption that the thermal properties of the thin film make very little contribution. In this paper we take mirage technique as an example and present a detailed analysis of the influence of thin film thermal properties on absorption measurement. The results show that the traditional calibration method is not valid on surprisingly many situations. Our theoretical calculations are verified by experimental results, and the thin film coatings investigated in this work include both single and multiple layer samples. Based on the detailed studies, new calibration methods are proposed for absorption measurements by using thermal wave analysis.
Recent work is reported on the growth and characterization of boron nitride thin films on 1 cm2 Si (100) substrates by a newly developed reactive laser ablation technique. The exact nature of the resulting films is highly process dependent and is analyzed by ion channeling and Fourier transform infrared spectroscopy (FTIR). The thermal properties of these films are studied by thermal wave analysis, and they are found to be highly dependent on the crystallographic structure. This value is believed to be the best thermal conductivity measured for boron nitride films to date.
A description of preliminary experimental work, in which thickness of ceramic coatings is measured using pulse echo thermal wave imaging, is presented. The thermal wave measurement technique uses the time (relative to flash heating) at which the peak slope of the contrast curve occurs to determine the thickness of the coating layer, based on reflection of the thermal wave from the coating/substrate interface. Thermal wave thickness measurements are compared to measurements made (destructively) with a drill micrometer. Repeatability and precision of measurements are discussed.
We describe pulse-echo thermal wave imaging and present images of defects in fiber- reinforced polymers and ceramics. In addition we will show thermal images of propagating cracks in polymers.
Pulse-Echo Thermal Wave IR techniques have been presented at recent SPIE Thermosense Conferences. A brief review is presented along with applications to the detection of adhesion disbonds and corrosion defects in bonded aluminum lap joints. Results for both test panel specimens and aircraft panels are presented. The feasibility of utilizing the technique for rapid, contactless, wide area field inspection of aircraft is discussed. Examples from a recent field test on a B737 aircraft are presented.
Preliminary results on inversion of thermal wave images were presented at Thermosense XIV. A technique was introduced for removing the blurring of thermal wave images of planar subsurface features such as delaminations. At that time the technique was limited to the case of thermally isotropic materials, and also ignored multiple scattering effects. In this paper we extend the inversion technique to take into account both anisotropy and multiple scattering. An application to an anisotropic composite is presented.
Thermal wave imaging (TWI) has typically relied upon HgCdTe optomechanical scanning radiometers in the 8 - 12 micrometers spectral range for image acquisition. However, recent improvements in manufacturing technology, spatial resolution, and device efficiency make PtSi and InSb focal plane array (FPA) cameras an attractive alternative in the 2 - 5 micrometers spectral range. We have compared the performance of off-the-shelf imagers of both scanning HgCdTe, and PtSi and InSb FPA types, in typical TWI applications, such as boxcar image processing of plastics and metals. The relative merits of detecting transient surface temperature variations in the 2 - 5 and 8 - 12 micrometers bands are discussed.
An outstanding problem of thermal wave imaging has been the blurring of the images caused by lateral diffusion of heat in the sample. In this paper we describe a technique for removing this blurring in images of planar subsurface features such as delaminations. This technique is based on a model which allows us to develop an algorithm which performs a mathematical inversion of the scattering process when it is applied to experimental data. The result is a theoretical and experimental demonstration that the blurring of thermal wave images is not due to any inherent loss of information in the diffusion process, but that it can, in fact, be removed by appropriate processing of the image. The result is a very significant improvement of the resolution of the imaging process.
We present applications of our infrared thermal wave imaging system which was described in detail at Thermosense XII. In brief, the system consists of an infrared video camera and a real time image processor under the control of a computer workstation, together with various time- dependent heat sources. The heat sources are used to launch pulsed or periodic thermal waves into the target, and the camera is used to record the thermal waves scattered back to the surface by sub-surface thermal features (cracks, coating substrate boundaries, inter-ply delaminations, etc.). Recently we have succeeded in developing an additional capability for this instrumentation, namely the ability to make quantitative depth and thickness measurements. Furthermore, some of the authors, together with V. Vavilov of Tomsk Polytechnic, have demonstrated a capability of carrying out thermal wave tomography. We have recently extended this technique to real time with our system. We describe these recent developments and present several applications to the study of thickness variations and adhesion defects in coatings and composites.
KEYWORDS: Image processing, Video, Cameras, Signal processing, Video processing, Infrared imaging, Signal to noise ratio, Thermography, Imaging systems, Copper
We describe an infrared (IR) imaging system in which noise suppression and image enhancement
occur as a result of real-time processing techniques, synchronized with active time-dependent heating of
the target. The system consists of an JR video camera and a real time image processor under the control
of a computer workstation, together with various time-dependent heat sources. The heat sources are used
to launch pulsed or periodic thermal waves into the target, and the camera is used to record the thermal
waves scattered back to the surface by sub-surface thermal features (cracks, coating substrate boundaries,
inter-ply delaminations, etc.). The technique involves applying either a sequence of short (-S. 5 ms) heat
pulses with relatively long time intervals between them, or a long train of square or sinusoidal heating
pulses with frequencies of a few Hz to a few kHz. In the first (pulsed) case, the signal processor is
operated as a pixel-by-pixel box-car averager with images being taken in several gated time windows after
each pulse. After averaging over multiple pulses, and suitable arithmetic manipulation of the gated
images, a resultant image with increased contrast and a considerably higher signal-to-noise ratio is
obtained. The result is as if a quarter of a million box-car averagers (one for each pixel of the image) had
processed the data. In the second (periodic heating) case, the system is operated as if it consisted of a
similar number of vector lock-in amplifiers, again producing an improved signal-to-noise ratio. We show
examples of sub-surface features in graphite-epoxy laminates and copper printed circuit traces embedded
in polyimide.
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