Impact Damage Evaluation in Composite Structures Based on Fusion of Results of Ultrasonic Testing and X-ray Computed Tomography

Barely visible impact damage (BVID) is one of the most dangerous types of structural damage in composites, since in most practical cases the application of advanced non-destructive testing (NDT) methods is required to detect and identify it. Due to its character of propagation, there are minor signs of structural damage on a surface, while the internal damage can be broad and complex both in the point of view of fracture mechanisms and resulting geometry of damage. The most common NDT method applied e.g., in aircraft inspections is ultrasonic testing (UT), which enables effective damage detection and localization in various environments. However, the results of such inspections are usually misestimated with respect to the true damage extent, and the quantitative analysis is biased by an error. In order to determine the estimation error a comparative analysis was performed on NDT results obtained for artificially damaged carbon fiber-reinforced composite structures using two UT methods and X-ray computed tomography (CT). The latter method was considered here as the reference one, since it gives the best spatial resolution and estimation accuracy of internal damage among the available NDT methods. Fusing the NDT results for a set of pre-damaged composite structures with various energy values of impact and various types of impactor tips applied for introducing damage, the evaluation of estimation accuracy of UT was possible. The performed analysis allowed for evaluation of relations between UT and X-ray CT NDT results and for proposal of a correcting factor for UT results for BVID in the analyzed composite structures.