This paper presents a new methodology for detecting various types of composite damage, such as delamination and impact damage, through the application of multimode guided waves. The basic idea is that various wave modes have different interactions with various types of composite damage. Using this method, selective excitations of pure-mode guided waves were achieved using adjustable angle beam transducers (ABTs). The tuning angles of various wave modes were calculated using Snell’s law applied to the theoretical dispersion curves of composite plates. Pitch–catch experiments were conducted on a 2-mm quasi-isotropic carbon fiber-reinforced polymer (CFRP) composite plate to validate the excitations of pure fundamental symmetric mode (S0) and shear horizontal mode (SH0). The generated pure S0 mode and SH0 mode were used to detect and separate the simulated delamination and actual impact damage. It was observed that S0 mode was only sensitive to the impact damage, while SH0 mode was sensitive to both simulated delamination and impact damage. The use of pure S0 and SH0 modes allowed for damage separation. In addition, the proposed method was applied to a 3-mm-thick quasi-isotropic CFRP composite plate using multimode guided wave detection to distinguish between delamination and impact damage. The experimental results demonstrated that the proposed method has a good capability to detect and separate various damage types in composite structures.

Barely visible impact damage (BVID) due to low velocity impact events in composite aircraft structures are becoming prevalent. BVID can have an adverse effect on the strength and safety of the structure. During aircraft inspections it can be extremely difficult to visually detect BVID. Moreover, it is also a challenge to ascertain if the BVID has in-fact caused internal damage to the structure or not. This paper describes a method to ascertain whether or not internal damage happened during the impact event by analyzing the high-frequency information contained in the recorded acoustic emission signal signature. Multiple 2 mm quasi-isotropic carbon fiber reinforced polymer (CFRP) composite coupons were impacted using the ASTM D7136 standard in a drop weight impact testing machine to determine the mass, height and energy parameters to obtain approximately 1” impact damage size in the coupons iteratively. For subsequent impact tests, four piezoelectric wafer active sensors (PWAS) were bonded at specific locations on each coupon to record the acoustic emission (AE) signals during the impact event using the MISTRAS micro-II digital AE system. Impact tests were conducted on these instrumented 2 mm coupons using previously calculated energies that would create either no damage or 1” impact damage in the coupons. The obtained AE waveforms and their frequency spectrums were analyzed to distinguish between different AE signatures. From the analysis of the recorded AE signals, it was verified if the structure had indeed been damaged due to the impact event or not. Using our proposed structural health monitoring technique, it could be possible to rapidly identify impact events that cause damage to the structure in real-time and distinguish them from impact events that do not cause damage to the structure. An invention disclosure describing our acoustic emission structural health monitoring technique has been filed and is in the process of becoming a provisional patent.

The manufacturing process of carbon fiber reinforced polymer (CFRP) composite structures can introduce many characteristic defects and flaws such as fiber misorientation, fiber waviness, and wrinkling. Therefore, it becomes increasingly important to detect the presence of these defects at the earliest stages of development. Eddy current testing (ECT) is a nondestructive inspection (NDI) technique that has been proven quite effective in detection of damage in metallic structures. However, NDI of composite structures has mainly relied on other methods such as ultrasonic testing (UT) and X-ray to name a few and not much on ECT. In this paper, the authors explore the possibility of using ECT in NDI of CFRP composites by conducting simulations and experiments thereafter. This research is based on the fact that the CFRP displays some low-level electrical conductivity due to the inherent conductivity of the carbon fibers. This low-level conductivity may permit eddy current pathways to cause the flow of eddy currents in the CFRP composites that can be exploited for nondestructive damage detection. An invention disclosure describing our high-frequency ECT method has also been processed. First, the multiphysics finite element method (FEM) simulation was used to simulate the detection of various types of manufacturing flaws and operational damage in CFRP composites such as fiber misorientation, waviness, wrinkling, and so on. Thereafter, ECT experiments were conducted on CFRP specimens with various manufacturing flaws using the Eddyfi Reddy eddy current array (ECA) system.