Composite materials are becoming more popular in the aerospace industry, because of their physical properties. In quality assurance and in-service inspection, there is a need for fast, non-contact, high-quality, non-destructive inspection techniques. The most common approach is to perform the inspection using water-coupled high-frequency transducers. Full wavefield techniques are promising to replace the conventional inspection approach. However, these are currently performed by a laser vibrometer setup, which has drawbacks. As an alternative, a low-cost micro-electro-mechanical system (MEMS) sensor array and dedicated processing scheme are presented enabling fast inspection of large samples. This inspection approach uses a piezoelectric actuator to excite the composite or metallic part with Lamb waves. An array of MEMS sensors records the energy that radiates into the surrounding air. A dedicated processing scheme will translate the measured wavefield into a thickness map of the inspected part. For composite parts, the material’s anisotropy needs to be taken into account for accurate thickness mapping. In principle, all relevant defects show up as local thickness reductions. The results in this paper are obtained with a MEMS-sensor array of 128 elements capable of detecting ultrasound up to 250 kHz at a typical stand-off distance of 100 mm. Defects up to 6 mm in diameter could be detected in thick panels, and defects as small as 2.5 mm could be detected in thin panels. A full-size fuselage experiment shows that the method is also suited for fast inspection of large inspection areas.

Routine maintenance of commercial aircraft requires reliable detection and repair of corrosion to ensure structural integrity. Post-repair inspections are commonly performed using manual ultrasonic point measurements of residual thickness, a process that is time-intensive and constrained by limitations in accuracy, repeatability, and cost. This study reports initial results of a non-contact, ultrasonic Lamb-wave-based inspection method, implemented with a mobile prototype system. The prototype integrates scanning, data acquisition, and reporting into a mobile workstation to support automated corrosion-repair inspections. Field trials validated the underlying measurement principle, while highlighting challenges when subsurface structures interfere with skin-only thickness evaluation.