Automated ultrasonic inspection of aerospace composites with enhanced defect detection probabilities aided by gantry deployed, CAD controlled robotics (AutoDISC)

Future generation aircraft will consist mostly of carbon composite materials. The modes of failure in composite intensive aircraft are not fully understood as they are still near the beginning of their design life, although it is clear that they are susceptible to internal impact damage, not visible at the surface. Yet current non-destructive inspection (NDI) of composites in production and service is still largely manual with low area coverage and NDI images are difficult to interpret for any technique because of macroscopic structural anisotropy.

AutoDISC proposes two key non-destructive inspection innovations. Up to 100% NDI coverage using gantry deployed, CAD controlled robotics, so that inspection records can be accurately compared at successive maintenance downtime intervals, to allow health diagnostics and prognostics. The second innovation is a step increase in current detection probability for composite defects, implemented through an inference engine performing similarity analysis on spatial and temporal changes in images, with coherent noise removal performed by advanced signal processing.

Short Title: AutoDISC
Project Number: 101800
Project Cost: £2,000,000
End Date: 31st Jul 2017
Time Horizon: Secure
Lead Partner: Plant Integrity Limited
Attributes: Safety, Cost
ATI Value Stream: Aerostructures of the future