Non-Destructive Evaluation of Defects and Damage in Composite Materials and Structures

The mechanical behaviour of composite materials differs from that of conventional structural materials owing to their heterogeneous and anisotropic nature. Different types of defects and anomalies get induced in these materials during the fabrication process. Further, during their service life, the components made of composite materials develop different types of damage. The performance and life of such components is governed by the combined effect of all these defects and damage. While porosity, voids, inclusions etc., are some defects those can get induced during the fabrication of composites, matrix cracks, interface debonds, delaminations and fiber breakage are major types of service induced damage which are of concern. During the service life of components made of composites, one type of damage can grow and initiate another type of damage. For example, matrix cracks can gradually grow to the interface and initiate debonds. Interface debonds in a particular plane can lead to delaminations. Consequently, the combined effect of different types of distributed damage causes the failure of the component. A set of non-destructive evaluation (NDE) methods is well established for testing conventional metallic materials. Some of them can also be utilized for composite materials as they are, and in some cases with a little different approach or modification. Ultrasonics, Radiography, Thermography, Fiber Optics, Acoustic Emision Techniques etc., to name a few. Detection, evaluation and characterization of different types of defects and damage encountered in composite materials and structures using different NDE tools is discussed briefly in this paper.

Non-destructive evaluation of photovoltaic materials and solar cells using Photoluminescence

Photoluminescence (PL) spectroscopy is an optical technique that has emerged successful in the field of semiconductor material and device characterization. This technique is quite a powerful one which gives idea about the defect levels in a material, the band gap of the material, composition as well as material quality. Over the recent years it has received an elevation as a mainstream characterization technique. This thesis is an attempt to characterize each individual layer used in a thin film solar cell with special focus on the electrical properties. This will be highly beneficial from the lab as well as industrial point of view because electrical measurements generally are contact mode measurements which tend to damage the surface. As far as a thin film solar cell is concerned, the constituent layers are the transparent conducting oxide (TCO), absorber layer, buffer layer and top electrode contact. Each layer has a specific role to play and the performance of a solar cell is decided and limited by the quality of each individual layer. Various aspects of PL spectroscopy have been employed for studying compound semiconductor thin films [deposited using chemical spray pyrolysis (CSP)] proposed for solar cell application. This thesis has been structured in to seven chapters

Desenvolvimento de um núcleo versátil e integrado de ferramentas CAD/CAE para a modelagem e simulação de peças mecânicas

Currently there is still a high demand for quality control in manufacturing processes of mechanical parts. This keeps alive the need for the inspection activity of final products ranging from dimensional analysis to chemical composition of products. Usually this task may be done through various nondestructive and destructive methods that ensure the integrity of the parts. The result generated by these modern inspection tools ends up not being able to geometrically define the real damage and, therefore, cannot be properly displayed on a computing environment screen. Virtual 3D visualization may help identify damage that would hardly be detected by any other methods. One may find some commercial softwares that seek to address the stages of a design and simulation of mechanical parts in order to predict possible damages trying to diminish potential undesirable events. However, the challenge of developing softwares capable of integrating the various design activities, product inspection, results of non-destructive testing as well as the simulation of damage still needs the attention of researchers. This was the motivation to conduct a methodological study for implementation of a versatile CAD/CAE computer kernel capable of helping programmers in developing softwares applied to the activities of design and simulation of mechanics parts under stress. In this research it is presented interesting results obtained from the use of the developed kernel showing that it was successfully applied to case studies of design including parts presenting specific geometries, namely: mechanical prostheses, heat exchangers and piping of oil and gas. Finally, the conclusions regarding the experience of merging CAD and CAE theories to develop the kernel, so as to result in a tool adaptable to various applications of the metalworking industry are presented

Non-destructive genetic sampling in fish. An improved method for DNA extraction from fish fins and scales

DNA-based studies have been one of the major interests in conservation biology of endangered species and in population genetics. As species and population genetic assessment requires a source of biological material, the sampling strategy can be overcome by non-destructive procedures for DNA isolation. An improved method for obtaining DNA from fish fins and scales with the use of an extraction buffer containing urea and further DNA purification with phenol-chloroform is described. The methodology combines the benefits of a non-destructive DNA sampling and its high efficiency. In addition, comparisons with other methodologies for isolating DNA from fish demonstrated that the present procedure also becomes a very attractive alternative to obtain large amounts of high-quality DNA for use in different molecular analyses. The DNA samples, isolated from different fish species, have been successfully used on random amplified polymorphic DNA (RAPD) experiments, as well as on amplification of specific ribosomal and mitochondrial DNA sequences. The present DNA extraction procedure represents an alternative for population approaches and genetic studies on rare or endangered taxa.

Magnetic non-destructive evaluation of ruptures of tensile armor in oil risers

Risers are flexible multilayered pipes formed by an inner flexible metal structure surrounded by polymer layers and spiral wound steel ligaments, also known as armor wires. Since these risers are used to link subsea pipelines to floating oil and gas production installations, and their failure could produce catastrophic consequences, some methods have been proposed to monitor the armor integrity. However, until now there is no practical method that allows the automatic non-destructive detection of individual armor wire rupture. In this work we show a method using magnetic Barkhausen noise that has shown high efficiency in the detection of armor wire rupture. The results are examined under the cyclic and static load conditions of the riser. This work also analyzes the theory behind the singular dependence of the magnetic Barkhausen noise on the applied tension in riser armor wires.

Experimental assessment of environmental decay effects in masonry via non destructive diagnostic techniques and mechanical tests

Environmental decay in porous masonry materials, such as brick and mortar, is a widespread problem concerning both new and historic masonry structures. The decay mechanisms are quite complex dependng upon several interconnected parameters and from the interaction with the specific micro-climate. Materials undergo aesthetical and substantial changes in character but while many studies have been carried out, the mechanical aspect has been largely understudied while it bears true importance from the structural viewpoint. A quantitative assessment of the masonry material degradation and how it affects the load-bearing capacity of masonry structures appears missing. The research work carried out, limiting the attention to brick masonry addresses this issue through an experimental laboratory approach via different integrated testing procedures, both non-destructive and mechanical, together with monitoring methods. Attention was focused on transport of moisture and salts and on the damaging effects caused by the crystallization of two different salts, sodium chloride and sodium sulphate. Many series of masonry specimens, very different in size and purposes were used to track the damage process since its beginning and to monitor its evolution over a number of years Athe same time suitable testing techniques, non-destructive, mini-invasive, analytical, of monitoring, were validated for these purposes. The specimens were exposed to different aggressive agents (in terms of type of salt, of brine concentration, of artificial vs. open-air natural ageing, …), tested by different means (qualitative vs. quantitative, non destructive vs. mechanical testing, punctual vs. wide areas, …), and had different size (1-, 2-, 3-header thick walls, full-scale walls vs. small size specimens, brick columns and triplets vs. small walls, masonry specimens vs. single units of brick and mortar prisms, …). Different advanced testing methods and novel monitoring techniques were applied in an integrated holistic approach, for quantitative assessment of masonry health state.

Non-destructive optical characterisation of fruits with time-resolved reflectance spectroscopy.

Increasing attention is being paid to the possible development of non-invasive tests for the assessment of the quality of fruits We propose a novel non-destructive method for the measurement of the internal optical properties of fruits and vegetables by means of time resolved reflectance spectroscopy in the visible and NIR range. A fully automated instrumentation for time-resolved reflectance measurements was developed It is based on mode-locked laser sources and electronics for time-correlated single photon counting, and provides a time-resolution of 120-160 ps The system was used to probe the optical properties of several species and varieties of fruits and vegetables in the red and NIR range (650-1000 nm). In most fruits, the absorption line shape is dominated by the absorption peak of water, centred around 970 nm Generally, the absorption spectra also show the spectral features typical of chlorophyll, with maximum at 675 nm In particular, for what concerns apples, variations in peak intensity are observed depending on the variety, the degree of ripeness as well as the position on the apple. For all the species and varieties considered, the transport scattering coefficient decreases progressively upon increasing the wavelength.

Non-destructive optical characterization of fruits in the red and near infrared.

Increasing attention is being paid to the possible development of non-invasive tests for the assessment of the quality of Fruits. We propose a novel non-destructive method for the measurement of the internal optical properties of fruits and vegetables by means of lime-resolved reflectance spectroscopy in the visible and NIR range. A Fully automated instrumentation for time-resolved reflectance measurements was developed. It is based on mode-locked laser sources and electronics for time-correlated single photon counting, and provides a time-resolution of 120-160 ps. The system was used to probe the optical properties of several species and varieties of Fruits and vegetables in the red and NIR range (650-1000 nm). In most Fruits, the absorption line shape is dominated by the absorption peak of water, centred around 970 nm. Generally, the absorption spectra also show the spectral features typical of chlorophyll, with maximum at 675 nm. In particular, for what concerns apples, variations in peak intensity are observed depending on the variety, the degree of ripeness as well as the position on the apple. For all the species and varieties considered, the transport scattering coefficient decreases progressively upon increasing the wavelength.

Determination of firmness in a fruit packing line using a non destructive impact sensor.

The increasing of quality fruit demanded by the consumers is originating an advance in the development and application of sensors capable of measuring parameters of quality (sugar, acids, firmness, etc) on a non destructive way. Some of these sensors are already operative for their use in laboratory and even in lines. The Physical Properties laboratory of the Polytechnic University of Madrid, is developing different sensors for their implementation in lines. One of them is a non destructive impact sensor to measure fruit firmness.

Optimización de aperturas mediante técnicas de algoritmos evolutivos

Los sistemas de imagen por ultrasonidos son hoy una herramienta indispensable en aplicaciones de diagnóstico en medicina y son cada vez más utilizados en aplicaciones industriales en el área de ensayos no destructivos. El array es el elemento primario de estos sistemas y su diseño determina las características de los haces que se pueden construir (forma y tamaño del lóbulo principal, de los lóbulos secundarios y de rejilla, etc.), condicionando la calidad de las imágenes que pueden conseguirse. En arrays regulares la distancia máxima entre elementos se establece en media longitud de onda para evitar la formación de artefactos. Al mismo tiempo, la resolución en la imagen de los objetos presentes en la escena aumenta con el tamaño total de la apertura, por lo que una pequeña mejora en la calidad de la imagen se traduce en un aumento significativo del número de elementos del transductor. Esto tiene, entre otras, las siguientes consecuencias: Problemas de fabricación de los arrays por la gran densidad de conexiones (téngase en cuenta que en aplicaciones típicas de imagen médica, el valor de la longitud de onda es de décimas de milímetro) Baja relación señal/ruido y, en consecuencia, bajo rango dinámico de las señales por el reducido tamaño de los elementos. Complejidad de los equipos que deben manejar un elevado número de canales independientes. Por ejemplo, se necesitarían 10.000 elementos separados λ 2 para una apertura cuadrada de 50 λ. Una forma sencilla para resolver estos problemas existen alternativas que reducen el número de elementos activos de un array pleno, sacrificando hasta cierto punto la calidad de imagen, la energía emitida, el rango dinámico, el contraste, etc. Nosotros planteamos una estrategia diferente, y es desarrollar una metodología de optimización capaz de hallar de forma sistemática configuraciones de arrays de ultrasonido adaptados a aplicaciones específicas. Para realizar dicha labor proponemos el uso de los algoritmos evolutivos para buscar y seleccionar en el espacio de configuraciones de arrays aquellas que mejor se adaptan a los requisitos fijados por cada aplicación. En la memoria se trata el problema de la codificación de las configuraciones de arrays para que puedan ser utilizados como individuos de la población sobre la que van a actuar los algoritmos evolutivos. También se aborda la definición de funciones de idoneidad que permitan realizar comparaciones entre dichas configuraciones de acuerdo con los requisitos y restricciones de cada problema de diseño. Finalmente, se propone emplear el algoritmo multiobjetivo NSGA II como herramienta primaria de optimización y, a continuación, utilizar algoritmos mono-objetivo tipo Simulated Annealing para seleccionar y retinar las soluciones proporcionadas por el NSGA II. Muchas de las funciones de idoneidad que definen las características deseadas del array a diseñar se calculan partir de uno o más patrones de radiación generados por cada solución candidata. La obtención de estos patrones con los métodos habituales de simulación de campo acústico en banda ancha requiere tiempos de cálculo muy grandes que pueden hacer inviable el proceso de optimización con algoritmos evolutivos en la práctica. Como solución, se propone un método de cálculo en banda estrecha que reduce en, al menos, un orden de magnitud el tiempo de cálculo necesario Finalmente se presentan una serie de ejemplos, con arrays lineales y bidimensionales, para validar la metodología de diseño propuesta comparando experimentalmente las características reales de los diseños construidos con las predicciones del método de optimización. ABSTRACT Currently, the ultrasound imaging system is one of the powerful tools in medical diagnostic and non-destructive testing for industrial applications. Ultrasonic arrays design determines the beam characteristics (main and secondary lobes, beam pattern, etc...) which assist to enhance the image resolution. The maximum distance between the elements of the array should be the half of the wavelength to avoid the formation of grating lobes. At the same time, the image resolution of the target in the region of interest increases with the aperture size. Consequently, the larger number of elements in arrays assures the better image quality but this improvement contains the following drawbacks: Difficulties in the arrays manufacturing due to the large connection density. Low noise to signal ratio. Complexity of the ultrasonic system to handle large number of channels. The easiest way to resolve these issues is to reduce the number of active elements in full arrays, but on the other hand the image quality, dynamic range, contrast, etc, are compromised by this solutions In this thesis, an optimization methodology able to find ultrasound array configurations adapted for specific applications is presented. The evolutionary algorithms are used to obtain the ideal arrays among the existing configurations. This work addressed problems such as: the codification of ultrasound arrays to be interpreted as individuals in the evolutionary algorithm population and the fitness function and constraints, which will assess the behaviour of individuals. Therefore, it is proposed to use the multi-objective algorithm NSGA-II as a primary optimization tool, and then use the mono-objective Simulated Annealing algorithm to select and refine the solutions provided by the NSGA I I . The acoustic field is calculated many times for each individual and in every generation for every fitness functions. An acoustic narrow band field simulator, where the number of operations is reduced, this ensures a quick calculation of the acoustic field to reduce the expensive computing time required by these functions we have employed. Finally a set of examples are presented in order to validate our proposed design methodology, using linear and bidimensional arrays where the actual characteristics of the design are compared with the predictions of the optimization methodology.

Survey of non-destructive tire inspection techniques. Preliminary memorandum.

National Highway Traffic Safety Administration, Washington, D.C.

Development and evaluation of a non-destructive adhesion test

The object of this work was to further develop the idea introduced by Muaddi et al (1981) which enables some of the disadvantages of earlier destructive adhesion test methods to be overcome. The test is non-destructive in nature but it does need to be calibrated against a destructive method. Adhesion is determined by measuring the effect of plating on internal friction. This is achieved by determining the damping of vibrations of a resonating specimen before and after plating. The level of adhesion was considered by the above authors to influence the degree of damping. In the major portion of the research work the electrodeposited metal was Watt's nickel, which is ductile in nature and is therefore suitable for peel adhesion testing. The base metals chosen were aluminium alloys S1C and HE9 as it is relatively easy to produce varying levels of adhesion between the substrate and electrodeposited coating by choosing the appropriate process sequence. S1C alloy is the commercially pure aluminium and was used to produce good adhesion. HE9 aluminium alloy is a more difficult to plate alloy and was chosen to produce poorer adhesion. The "Modal Testing" method used for studying vibrations was investigated as a possible means of evaluating adhesion but was not successful and so research was concentrated on the "Q" meter. The method based on the use of a "Q" meter involves the principle of exciting vibrations in a sample, interrupting the driving signal and counting the number of oscillations of the freely decaying vibrations between two known preselected amplitudes of oscillations. It was not possible to reconstruct a working instrument using Muaddi's thesis (1982) as it had either a serious error or the information was incomplete. Hence a modified "Q" meter had to be designed and constructed but it was then difficult to resonate non-magnetic materials, such as aluminium, therefore, a comparison before and after plating could not be made. A new "Q" meter was then developed based on an Impulse Technique. A regulated miniature hammer was used to excite the test piece at the fundamental mode instead of an electronic hammer and test pieces were supported at the two predetermined nodal points using nylon threads. This instrument developed was not very successful at detecting changes due to good and poor pretreatments given before plating, however, it was more sensitive to changes at the surface such as room temperature oxidation. Statistical analysis of test results from untreated aluminium alloys show that the instrument is not always consistent, the variation was even bigger when readings were taken on different days. Although aluminium is said to form protective oxides at room temperature there was evidence that the aluminium surface changes continuously due to film formation, growth and breakdown. Nickel plated and zinc alloy immersion coated samples also showed variation in Q with time. In order to prove that the variations in Q were mainly due to surface oxidation, aluminium samples were lacquered and anodised Such treatments enveloped the active surfaces reacting with the environment and the Q variation with time was almost eliminated especially after hard anodising. This instrument detected major differences between different untreated aluminium substrates.Also Q values decreased progressively as coating thicknesses were increased. This instrument was also able to detect changes in Q due to heat-treatment of aluminium alloys.

Establishing an EGFR mutation screening service for non-small cell lung cancer - sample quality criteria and candidate histological predictors.

INTRODUCTION: EGFR screening requires good quality tissue, sensitivity and turn-around time (TAT). We report our experience of routine screening, describing sample type, TAT, specimen quality (cellularity and DNA yield), histopathological description, mutation result and clinical outcome. METHODS: Non-small cell lung cancer (NSCLC) sections were screened for EGFR mutations (M+) in exons 18-21. Clinical, pathological and screening outcome data were collected for year 1 of testing. Screening outcome alone was collected for year 2. RESULTS: In year 1, 152 samples were tested, most (72%) were diagnostic. TAT was 4.9 days (95%confidence interval (CI)=4.5-5.5). EGFR-M+ prevalence was 11% and higher (20%) among never-smoking women with adenocarcinomas (ADCs), but 30% of mutations occurred in current/ex-smoking men. EGFR-M+ tumours were non-mucinous ADCs and 100% thyroid transcription factor (TTF1+). No mutations were detected in poorly differentiated NSCLC-not otherwise specified (NOS). There was a trend for improved overall survival (OS) among EGFR-M+ versus EGFR-M- patients (median OS=78 versus 17 months). In year 1, test failure rate was 19%, and associated with scant cellularity and low DNA concentrations. However 75% of samples with poor cellularity but representative of tumour were informative and mutation prevalence was 9%. In year 2, 755 samples were tested; mutation prevalence was 13% and test failure only 5.4%. Although samples with low DNA concentration (2.2 ng/μL), the mutation rate was 9.2%. CONCLUSION: Routine epidermal growth factor receptor (EGFR) screening using diagnostic samples is fast and feasible even on samples with poor cellularity and DNA content. Mutations tend to occur in better-differentiated non-mucinous TTF1+ ADCs. Whether these histological criteria may be useful to select patients for EGFR testing merits further investigation.

Ranking of fibre-reinforced composite plate surface finish quality by wavelet texture analysis

In the automotive and other industries, the visual appearance of external surfaces is a key factor in perceived product quality. Traditionally, the quality of an automotive surface finish has been judged by expert human auditors. A set of 17 fibre-reinforced composite plates was previously manufactured to have a range of surface finish qualities and these plates were ranked by three expert observers and also optically digitally imaged. Following validation of the previous rankings, the wavelet texture analysis (WTA) technique was applied to the digital photographs to derive an instrumental measure of surface finish quality based on the panel images. The rank correlation between the human expert surface finish quality ratings and those from the W TA image analysis process was found to be positive, large and statistically significant. This finding indicates that WTA could form the basis of an inexpensive and practical instrumental method for the ranking of fibre-reinforced composite surface finish quality.