Other Aerospace Applications

Composite Airplane Parts

R/D Tech has delivered complete systems for the inspection
of composite material panels. These systems can inspect
many different types of parts, looking for typical defects
found in composite material (for ex. disbonding).

PHASED ARRAY ULTRASONIC

SYSTEM FOR INSPECTION OF
FRICTION STIR WELDS
General description of the application
The friction stir welding (FSW) technique was
developed as a method to join materials that are
difficult to fusion weld such as aluminum alloys.
The quality of the obtained weld is very high,
tests show that there are no pores in the weld
and the material structure is uniform. However,
the process may generate small, tight defects that
are hard to detect.

In order to scan complex shapes, a multiaxis robot is

often used. The scan pattern can be acquired from CATIA
CAD files or automatically learned (teach mode). Once
the shape is memorized, the part is automatically scanned
with ultrasound at speeds of up to 330 mm/s. Inspections
can be performed in pulse echo or through transmission
modes.

The best method to inspect friction stir welds is to

use the ultrasonic phased array technique. Because
of the weld shape, raster scanning is impossible;
but with phased arrays, inspection of the entire
weld volume is done in a single-pass scan.

Turbine Disc Roots (Dovetails)

Phased arrays also permit lateral scanning to detect

transverse defects. Optimization of the inspection
angle maximizes the probability of detection. The
increased number of zones covered by phased
arrays provides accurate flaw sizing and location.
High speed, accuracy, and versatility make phased
arrays the choice technique for FSW inspection.

R/D Tech array probe technology allows quick manual

scanning of complex surfaces such as turbine disc roots.
Here a 48-coil array probe, manufactured with the same
shape as the dovetail, is used to provide a complete
image of the surface with a single pass of the probe. This
powerful technique considerably reduces inspection time
while increasing inspection quality with thorough coverage.
The software provides a complete inspection record.
The same technique can be used for other complex shapes
such as booster rocket matching joints.

Representatives worldwide Contact us for more information or to discuss your applications.

R/D Tech Head Office
Qubec, Canada
Tel.: (1) (418) 872-1155

R/D Tech USA

Lexington, USA
Tel.: (1) (781) 676 -7771

R/D Tech Europe

Villebon-sur-Yvette, France
Tel.: (33) (0) 1 69 18 99 20

R/D Tech Asia

Tokyo, Japan
Tel.: (81) (0) 35 614 4330

www.rd-tech.com
R/D Tech, the R/D Tech logo, and R/D Tech products are trademarks of R/D Tech inc. All other products are trademarks and registered trademarks of their respective owners.

Aerospace
Application
Note
Rev.: 2002-05

Typical inspection requirements

Analysis and reporting using TomoView software

Weld length: up to 40 feet

Wall thickness: 3 to 15 mm (or more)
Diameter range: 8 to 17 feet
Material: aluminum (although this technology can be used on any material welded by FSW)
Vertical or horizontal configuration
Irregular weld shape hindering raster scanning
Limited access space
Coupling check required
Fully automated inspection

All of R/D Tech ultrasound products, whether using phased array, ultrasound, or EMAT, share the same data acquisition
and analysis software. The software is PC-based and can be used on standard PCs ranging from simple laptops to powerful
multiprocessor workstations.

Data acquisition and analysis

Defects detected
Lack of penetration
Kissing bonds
Wormholes
Root toe defect
Axial and transverse defects
Porosity

Description of the solution

One probe on each side of the weld for axial
detection, plus a third probe for
transverse detection
Motorized positioning of the probe
(weld centering)
Inspection with 65 SW and 45 SW for axial
defects
Inspection with 45 SW refraction angle and skew
angles of -30, 0, and 30 for transverse defects
Electronic scanning of the beam
for all configurations
Whole inspection performed as a one-line scan
(up to 70 feet)
Coupling is performed with local immersion wedges

Microstructure of the weld.

Microstructure of a defect: kissing bond.

Software setup and control of the acquisition

system
Easy programming of focal laws for sector, linear,
and depth scans as well as dynamic depth
focusing
Automatic volumetric settings
Real-time display of A-scans, B-scans, C-scans,
and D-scans
Real-time display of phased array sector scans
Real-time display of angle-corrected, top, side, and
end views from either A-scan, C-scan, or peak data
Real-time imaging with part drawing overlay
Analysis may proceed simultaneously with data
acquisition
Measurement cursors and time-of-flight diffraction
measurement tools
Scanner control for automated inspections

Top view (C-scan)

Each probe produces many different refraction angle at 0 LW for coupling check
performed with the same probe.

End view (D-scan)

Side view (B-scan)

Material requirements

Top, side, and end views of a scan detecting a root toe defect.

FOCUS 32:128: ultrasonic phased array system

Scanner: ROVER with special adapter
Power driver: MCDU-02 with joystick
Probes: 3 10-MHz, 64-element probes
Wedges: local immersion wedges
Water recirculation system
Umbilical cable with air, 110 VAC, scanner control,
and UT signal
Air compressor
Portable track for autonomous work
Computer and air-conditioned cabinet

FOCUS 32:128, MCDU-02, and

computer all enclosed in an
air-conditioned cabinet.

Water recirculation system.

ROVER with special adapter.

10-MHz, 64-element probe with local

immersion wedge.