Quality Control Approach for the Detection of Internal Lower Density Areas in Composite Disks in Industrial Conditions Based on a Combination of NDT Techniques

Voids in polymer matrix composites are one of the most common manufacturing defects, which may influence the mechanical properties and structural behavior of the final parts made of composites by various manufacturing methods. Therefore, numerous non-destructive testing (NDT) techniques were developed and applied for quality control and in-service testing of such structures. In this paper, the authors analyzed various alternatives to the reference technique, X-ray computed tomography (XCT) NDT, which is used for industrial testing of composite disks having defects in the form of the lower density areas. Different candidates, namely: vibration-based testing, infrared thermography, vibro-thermography, as well as ultrasonic testing were analyzed in terms of their sensitivity and technical feasibility. The quality of the results, the complexity of the testing procedure, time and labor consumption, and the cost of the equipment were analyzed and compared with the reference technique. Based on the conducted research the authors finally proposed a hybrid approach to quality control, using a combination of two NDT techniques–infrared thermography (for initial scanning and detection of near-surface defects) and ultrasonic testing (for a more detailed analysis of products that pass the first testing procedure). It allowed for replacing the costly XCT diagnostics with a much cheaper, but almost equally effective, alternative.