A Novel Infrared Thermography Sensing Approach for Rapid, Quantitative Assessment of Damage in Aircraft Composites

The current necessity of the scientific and industrial community, for reduction of aircraft maintenance cost and duration, prioritizes the need for development of innovative nondestructive techniques enabling fast and reliable defect detection on aircraft fuselage and wing skin parts. Herein, a new low-cost thermographic strategy, termed Pulsed Phase-Informed Lock-in Thermography, operating on the synergy of two independent, active infrared thermography techniques, is reported for the fast and quantitative assessment of superficial and subsurface damage in aircraft-grade composite materials. The two-step approach relies on the fast, initial qualitative assessment, by Pulsed Phase Thermography, of defect location and the identification of the optimal material-intrinsic frequency, over which lock-in thermography is subsequently applied for the quantification of the damage’s dilatational characteristics. A state-of-the-art ultra-compact infrared thermography module envisioned to form part of a fully-automated autonomous nondestructive testing inspection solution for aircraft was conceived, developed, and tested on aircraft-grade composite specimens with impact damages induced at variable energy levels and on a full-scale aircraft fuselage skin composite panel. The latter task was performed in semi-automated mode with the infrared thermography module mounted on the prototype autonomous vortex robot platform. The timescale requirement for a full assessment of damage(s) within the sensor’s field of view is of the order of 60 s which, in combination with the high precision of the methodology, unfolds unprecedented potential towards the reduction in duration and costs of tactical aircraft maintenance, optimization of efficiency and minimization of accidents.