Modeling Ultrasound-Pore Interactions in Carbon Fiber-Reinforced Composites to Enhance Porosity Assessment Accuracy

Carbon fiber-reinforced composites (CFRC) are frequently used in the aerospace and automobile industries due to their high mechanical properties and lightweight. CFRC is typically made by impregnating layers of carbon fiber fabrics with liquid polymer precursors. The impregnated fabrics are shaped into a mold and the precursors are heat-converted, that is, cured into a solid polymer encapsulating the carbon fabric. The impregnation and curing process can be imperfect and lead to a porous CFRC. Porosity significantly compromises the mechanical properties of materials. Ultrasonic inspection is used to detect critical levels of porosity in CFRC to certify components. In ultrasonic testing, porosity can be estimated by measuring the acoustic attenuation in the material. Limitations of this technique are its inability to provide precise information on the morphology and distribution of porosity, and its reliance on a skilled operator and precise calibration procedures to obtain precise measurements. Tecscan, a leader in ultrasonic inspection, and Polytechnique Montreal, are joining to improve the shortcomings of current ultrasonic inspection techniques. The objective of this project is to develop a novel modeling approach of ultrasound-to-pore interaction in CFRC, improving the accuracy of the porosity assessment. This research project promises to be highly innovative in the field of NDT in Canada. In addition to enhancing the capabilities and applications of ultrasonic testing, it will increase the efficiency of maintaining and health-monitoring composite components, which is crucial in the aerospace industry. For Tecscan, this project will create opportunities to replace traditional ultrasonic test equipment with next-generation technology.

Faculty Supervisor:

Louis Laberge Lebel

Student:

Partner:

TecScan

Discipline:

Engineering

Sector:

Manufacturing

University:

Polytechnique Montréal

Program: