C-Flux

Innovative sensor technology for non-destructive evaluation of composites that can give sensitivities 1000 times greater than before, retrieving high-quality, high-resolution signals.

Existing non-destructive evaluation (NDE) methods currently add up to 10% to aerospace composites manufacturing time. With C-Flux being 30 times faster than manual ultrasonic systems, manufacturers moving from manual NDE to C-Flux automation could reduce this to below 1%, with associated costs reduced to just 0.6% of current manufacturing spend*.

To achieve this, the C-Flux project developed an innovative sensor technology that can give sensitivities 1000 times greater than before, retrieving high-quality, high-resolution signals. The small size of the technology makes it easy to develop into multi-sensor arrays that are resilient and flexible, ideal for use in the production-line robotics necessary to speed-up and reduce the cost of the inspection process.

The technical success achieved in the C-Flux project has highlighted the capability of Eddy current non-destructive testing (NDT) equipment to be used in the composite industry. It is a safe NDT method, does not need a couplant like ultrasonic to work, or emit harmful radiation like some x-ray methods.

During the C-Flux project, Eddy current scanners where mounted on modified gantries to be used on weaving looms to test the possibility of scanning the carbon fibre fabric for defects and embedded metal debris as it was being woven. This is with the aim of finding metal debris which can sometimes become embedded within the fabric earlier in the manufacturing process.

The C-Flux project has shown that it is possible to detect and locate defects in composites and further work is needed to develop better understanding of calibration, output and capabilities.

*Costs and time savings provided by M Wright & Sons.