Advanced Non-Destructive Inspections focused on composite materials application for the automotive and marine sectors

The goal of this master thesis is to explain in detail the application of Non-Destructive-Inspection on the Automotive and the Marine sectors. Nowadays, these two particular industries faces many challenges, including increased global competition, the need for higher performance, a reduction in costs and tighter environmental and safety requirements. The materials used for these applications play key roles in overcoming these challenges. So, also an NDI procedure need to be planned in order to avoid problems during the manufacturing process and the after sale life of the structures. The entire thesis work has been done in collaboration with Vetorix Engineering.

Damage tolerance analysis for Blackshape BS 115 programme, EASA CS VLA & CS-23

The thesis project has been developed in partnership with the Design Department of Blackshape Spa, a carbon – fiber ultra – light airplane company in Monopoli (Bari, Italy). The main goal is the assessment of a starting point for a damage tolerant concept during the design and certification phases of the Blackshape BS 115 airplane, with respect to EASA CS VLA & CS 23 Regulations. This approach has been carried out starting from an initial literary review as far as the way of modeling composites fractures is concerned. Further on, three finite element models have been generated and implemented in order to simulate defects occurring during manufacturing and service phases. At last, the procedures of non - destructive inspections have been taken into account, in order to establish how to investigate primary structures defects and delaminations during maintenance.

Analysis of aircraft load spectrum by means of flight simulator

Damage tolerance analysis is a quite new methodology based on prescribed inspections. The load spectra used to derive results of these analysis strongly influence the final defined inspections programs that for this reason must be as much as possible representative of load acting on the considered structural component and at the same time, obtained reducing both cost and time. The principal purpose of our work is in improving the actual condition developing a complete numerical Damage Tolerance analysis, able to prescribe inspection programs on typical aircraft critical components, respecting DT regulations, starting from much more specific load spectrum then those actually used today. In particular, these more specific load spectrum to design against fatigue have been obtained through an appositively derived flight simulator developed in a Matlab/Simulink environment. This dynamic model has been designed so that it can be used to simulate typical missions performing manually (joystick inputs) or completely automatic (reference trajectory need to be provided) flights. Once these flights have been simulated, model’s outputs are used to generate load spectrum that are then processed to get information (peaks, valleys) to perform statistical and/or comparison consideration with other load spectrum. However, also much more useful information (loads amplitude) have been extracted from these generated load spectrum to perform the previously mentioned predictions (Rainflow counting method is applied for this purpose). The entire developed methodology works in a complete automatic way, so that, once some specified input parameters have been introduced and different typical flights have been simulated both, manually or automatically, it is able to relate the effects of these simulated flights with the reduction of residual strength of the considered component.

Analysis ot the road barriers maintenance: the Bologna Case Study

This thesis deals with the topic of Road Safety when maintaining its road elements. The aim of the work is the prioritization of maintenance for each barrier that depends on some factors that are related to the topography of the site, deformations, degradation of the composing elements, and the compliance of the barrier installation with the original situation. Based on these components a final coefficient by which the maintenance priority was highlighted, calculated, and associated to each barrier. For easy study and visualization, information was uploaded and processed in a GIS environment, in order to create analyses and choropleth maps. Analyses were exploited by using free and open-source GIS software, namely QGIS. Information on the barriers' features was registered with both on-site and online (i.e., web mapping providers) inspections. With regards to the on-site inspections, a complete geotagged photos database was created, in order to improve the survey. GIS potentialities were fully exploited by applying some geoprocessing tools which allowed deep analyses.

Analysing Road Barrier using GIS Software: The Case Study of Bologna

The direct attention of this thesis is the maintenance of road elements to improve road safety. The goal of the research is to prioritise maintenance for barriers based on factors such as the terrain of the site, deformations, degradation of the components, and adherence to the original installation. Using these factors, a coefficient is calculated to determine the maintenance priority for each barrier. To ease understanding and visualisation, data was uploaded and processed in a GIS environment to generate analysis and maps. This was done using GIS, a free and open-source GIS software. Information about the features of the barriers was collected through both on-site and online examination. During on-site inspections, a database of geotagged photos was created to aid in the survey. GIS capabilities word fully utilised by using geoprocessing tools for more in-depth analysis.