This MEng (Master of Engineering) research thesis evaluates the capabilities and limitations of line-scan thermography for the non-destructive evaluation of composite structures containing hidden defects. In simple terms, line-scan thermography is a state-of-the-art technique in which a focused line of thermal energy is transmitted into a material. Line-scan thermography has great potential for the rapid and low cost non-destructive inspection of composite structures for aircraft, automobiles and ships. In this project, theoretical research exploring the heat transfer physics was undertaken in conjunction with experimental studies to develop an optimum inspection regime for line-scan thermography. The capability of line-scan thermography to detect impact damage in carbon/epoxy laminates was experimentally investigated in Chapter 3. From the impact side, in all materials, line-scan thermography overestimated the size of the impact damage whereas flash thermography underestimated the size. There was a close relationship between the ultrasonic profile and the line-scan thermographic thermal response curve. New experimental data has been produced and analysed for the ability of line-scan thermography to determine the defect as well as the defect size. It was found that line-scan thermography was able to distinguish back drilled holes, but it was not possible to determine accurate defect sizing due to the depth of the holes from the inspected surface and the limitations associated with the line-scan thermographic apparatus itself. There was excellent correlation between the C-scan ultrasonics intensity curves and the line-scan thermographs as well as excellent correlation with the theoretical results. The relationship between line-scan thermography and foreign body objects were experimentally investigated for carbon/epoxy composites. A major limitation found with line-scan thermography is its limited depth penetration, which is highlighted in the foreign object study using 6 mm and 13 mm diameter Teflon® discs and 13 mm Teflon® strips embedded in carbon/epoxy laminates. Depth penetration allowed only 2 mm resolution for the 13 mm diameter discs and 1.5 mm resolution for the 6 mm discs in a composite panel. The results of the investigation of stainless steel shim objects in carbon/epoxy laminates reveal that line-scan thermography is capable of determining their presence and size close to the surface. There was also excellent correlation between the ultrasonic response curve and the line-scan thermographic intensity curve. The results of the investigation of thermoplastic film foreign body objects in carbon/epoxy laminates show that at present line-scan thermography does not have the capability to determin e such defects. Experimental results show that line-scan thermography is capable of detecting large voids, back drilled holes, some foreign body objects, and impact damage. However, the ability of line-scan thermography to measure the defect dimensions is dependent on the size and type of damage, the distance from the line source, the depth of the defect, and the type of composite material.

The railroad industry is pivotal in the United States to ensure that the supply chain does not shut down for the American people. Non-Destruction Evaluation (NDE) approaches are preferred and performed on the railways to ensure the safety of the population that is exposed to the railway industry. When damage occurs on the rail base, there is an increased risk derailment of the train cars. Due to the nature of the railroad industry, there are challenges with developing a quick and reliable inspection method, along with the improvement of current NDE methods. The load, speed, and cycles of trains have increased the load that track sections endure over time. Some railways that were originally built in the early 20th century are still utilized today, designed for trains that are not nearly as heavy or fast as used today. Defects and damage on the railways lead to the need of development of an NDE approach utilizing Line Scan Thermography approaches. One of the most common defects that are formed are on the rail base is known as “base nicks” and “half-moon cracks”, these types of defects can occur over time. This research aims to study the feasibility of applying this NDE technique to detect defects that can occur on a rail base, both internal and external. For this research, a heat source up to 6000 W and tested velocities up to 447.1 mm/s (1.0 mph) are used to study the effects of line scanning thermography on various samples. In total, 10 samples are employed to test for feasibility: each one having a unique set of defects. Some defects fabricated on these samples are internal, such as bottom drilled holes (BDH) and side drilled holes (SDH); some of these samples are fabricated from actual rail samples. From tests conducted for internal defects, it can be concluded that defects with diameters of 6.35 mm (0.25”) can be detected at a remaining thickness from the observation surface of 6.35 mm. Along with internal defects, there are also external defects employed on the samples; these defects include simulated base nicks, fractures, and half-moon cracks. For surface defects tests from this research, it is found that the anomalies can be detected visually. The results from the experimental studies provide insight and limitations of LST for the possibility of a future commercial application.