Resistance spot welding is used frequently as a successful joining method for a variety of work commonly in automotive and other manufacturing processes. Spot weld nugget is generally hidden between two sheets, causing its inspection difficult and expensive. Undersized nuggets, brittle or cracked nuggets, and excessive indentation of electrodes reveals the lack of fusion between the parts that can make the weld sub-standard. Visual inspection, pry testing and physical teardown with chisel and hammer method or a combination of them are being used traditionally. However, this study presents a more effective nondestructive inspection method based upon an ultrasonic pulse-echo technique. The theory of the technique together with the experimental verification are presented and its advantages over the other destructive and nondestructive techniques are considered.

No description available.

The long-term goal of this research is to assist in the development of a fast, accurate, and low-cost nondestructive inspection prototype for solder joints in integrated circuits (IC). The goal of the work described in this thesis is to develop a fully automated system to maintain the signal strength of the vibrometer that would reduce the testing time while maintaining or improving the quality of the defect detection results. The ability to perform the inspections in an automated manner is very important in order to demonstrate the ability of the defect detection system to be used for online inspection without the need of an operator. The system was able to find the maximum signal strength (at a single point on the surface of a flip chip) nearly five times faster than Polytec's commercial system with a search time of approximately 2.1 sec. When integrated into the nondestructive inspection prototype, the system described in this work was found to approximately reduce the data acquisition time per test location by four times, with a minimum data acquisition time of 8.5 sec and an average time of 15.4 sec, while maintaining the same level of quality of results obtained by a skilled operator when manually maintaining the signal strength of the vibrometer. Hardware was developed that retrofitted a vibrometer's focusing head at the end of a fiber optic cable to a motorized linear stage. This stage controlled the standoff distance between the focusing head and the IC's surface with a fixed focal length, which allowed the spot size of the laser to be adjusted while searching for a desired signal strength. Numerous tests were conducted to determine the search parameters, which led to a search time of approximately 2.1 sec. This time was found to be dependent on the surface finish of the IC being inspected. It was also found that to achieve a desired signal intensity strength, not only does the standoff height of the focusing head, which determines the laser spot size, need to be controlled, but also the exact location on which the laser is reflecting off the IC.

京都大学 / 新制・課程博士 / 博士(エネルギー科学) / 甲第24254号 / エネ博第452号 / 新制||エネ||85(附属図書館) / 京都大学大学院エネルギー科学研究科エネルギー応用科学専攻 / (主査)教授 大垣 英明, 教授 白井 康之, 教授 宮内 雄平 / 学位規則第4条第1項該当 / Doctor of Energy Science / Kyoto University / DFAM

Diversos métodos de ensaios não-destrutivos (Ultrasom, Radiografia, Termografia e Shearografia) foram empregados na inspeção de peças laminadas estruturais compósitas sólidas de matriz polimérica manufaturadas pela indústria aeronáutica. Concluiu-se que Ultrasom pulso-eco convencional de contato foi a técnica mais abrangente na indicação de descontinuidades (danos/defeitos de manufatura) considerando-se peças planas e curvas, não obstante tenha falhado na detecção de trincas longas e bem definidas localizada na alma de componentes co-curados. Radiografia convencional por filmes exibiu um potencial interessante como método alternativo, ou complementar ao de Ultrasom. Termografia infravermelha foi a técnica mais veloz na indicação de descontinuidades, sendo uma valiosa alternativa para um mapeamento rápido em inspeções preliminares seguidas pela aplicação de técnicas complementares. Shearografia realizada com equipamento da empresa Photonita detectou inclusões em peça plana compósita, porém a interpretação dos resultados obtidos em geometrias mais complexas se mostrou duvidosa. O uso de equipamento shearográfico da empresa Dantec indicou posições em regiões curvas que podem estar associadas à presença de defeitos/danos locais, porém uma confirmação cabal desta relação não foi efetivada. Evidências visuais da profusa presença de danos/defeitos de manufatura, além da existência de detalhes construtivos nas peças compósitas mais complexas, sugerem que estas descontinuidades podem ter sensibilizado, em maior ou menor extensão, os equipamentos END, juntamente com a eventual presença de delaminações/falhas de adesão nas respectivas peças avaliadas. / Several nondestructive methods (Ultrasonics, Radiography, Thermography and Shearography) were employed for inspection of structural polymer matrix composite laminated parts manufactured by aircraft industry. Is has been concluded that conventional pulse-echo contact Ultrasonics was the most comprehensive technique to indicate discontinuities (manufacture damages/defects) in flat and curved parts, although it has failed to detect long and well-defined cracks in co-cured components. Conventional film radiography exhibited good potential as alternative or complementary method to Ultrasonics. Infrared thermography was the fastest technique to indicate discontinuities, so that it is a valuable option for rapid mapping in preliminary inspection followed by the application of complementary techniques. Sherography by means of Photonita equipment detected inclusions in flat panels, but the interpretation of results from pieces with more complex geometries was dubious. A shearographic of the Dantec device indicated positions in curved regions which might possibly be associated to the presence of damages/defects, however this relationship could not be definitively established. Visual evidences of the profuse existence of manufacture damages/defects, besides constructive details in more complex composite parts, suggest that theses discontinuities might have affected to some extent the NDT equipments, along with the eventual presence of delaminations/lack of adhesion on the respective evaluated parts.

Diversos métodos de ensaios não-destrutivos (Ultrasom, Radiografia, Termografia e Shearografia) foram empregados na inspeção de peças laminadas estruturais compósitas sólidas de matriz polimérica manufaturadas pela indústria aeronáutica. Concluiu-se que Ultrasom pulso-eco convencional de contato foi a técnica mais abrangente na indicação de descontinuidades (danos/defeitos de manufatura) considerando-se peças planas e curvas, não obstante tenha falhado na detecção de trincas longas e bem definidas localizada na alma de componentes co-curados. Radiografia convencional por filmes exibiu um potencial interessante como método alternativo, ou complementar ao de Ultrasom. Termografia infravermelha foi a técnica mais veloz na indicação de descontinuidades, sendo uma valiosa alternativa para um mapeamento rápido em inspeções preliminares seguidas pela aplicação de técnicas complementares. Shearografia realizada com equipamento da empresa Photonita detectou inclusões em peça plana compósita, porém a interpretação dos resultados obtidos em geometrias mais complexas se mostrou duvidosa. O uso de equipamento shearográfico da empresa Dantec indicou posições em regiões curvas que podem estar associadas à presença de defeitos/danos locais, porém uma confirmação cabal desta relação não foi efetivada. Evidências visuais da profusa presença de danos/defeitos de manufatura, além da existência de detalhes construtivos nas peças compósitas mais complexas, sugerem que estas descontinuidades podem ter sensibilizado, em maior ou menor extensão, os equipamentos END, juntamente com a eventual presença de delaminações/falhas de adesão nas respectivas peças avaliadas. / Several nondestructive methods (Ultrasonics, Radiography, Thermography and Shearography) were employed for inspection of structural polymer matrix composite laminated parts manufactured by aircraft industry. Is has been concluded that conventional pulse-echo contact Ultrasonics was the most comprehensive technique to indicate discontinuities (manufacture damages/defects) in flat and curved parts, although it has failed to detect long and well-defined cracks in co-cured components. Conventional film radiography exhibited good potential as alternative or complementary method to Ultrasonics. Infrared thermography was the fastest technique to indicate discontinuities, so that it is a valuable option for rapid mapping in preliminary inspection followed by the application of complementary techniques. Sherography by means of Photonita equipment detected inclusions in flat panels, but the interpretation of results from pieces with more complex geometries was dubious. A shearographic of the Dantec device indicated positions in curved regions which might possibly be associated to the presence of damages/defects, however this relationship could not be definitively established. Visual evidences of the profuse existence of manufacture damages/defects, besides constructive details in more complex composite parts, suggest that theses discontinuities might have affected to some extent the NDT equipments, along with the eventual presence of delaminations/lack of adhesion on the respective evaluated parts.

This study investigated the effect of sensor mass, sensor location, and delamination location of different composite structures under dynamic loading. The study pertains to research of the use of accelerometers and dynamic response as a cost-effective and reliable method of structural health monitoring in composite structures. The composite structures in this research included carbon fiber plates, carbon fiber-foam sandwich panels, and carbon-fiber honeycomb sandwich panels. The composite structures were manufactured with the use of a Tetrahedron MTP-8 heat press. All work was conducted in the Cal Poly Aerospace Structures/Composites Laboratory. Initial delaminations were placed at several locations along the specimen, including the bending mode node line locations. The free vibration of the composite structure was forced through a harmonic horizontal vibration test using an Unholtz-Dickie shake system. A sinusoidal sweep input was considered for the test. The dynamic response of the composite test specimens were measured using piezoelectric accelerometers. Measurements were taken along horizontal and vertical locations on the surfaces of the composite structures. Square inch grids were marked on the surfaces to create a meshed grid system. Accelerometer measurements were taken at the center of the grids. The VIP Sensors 1011A piezoelectric accelerometer was used to measure vibration response. The measurements were then compared to response measurements taken from a PCB Piezotronics 353B04 single access accelerometer to determine the effects of sensor mass. Deviations in bending mode natural frequency and differences in mode shape amplitude became the criteria for evaluating the effect of sensor mass, sensor location, and delamination location. Changes in damping of the time response were also studied. The experimental results were compared to numerical models created using a finite element method. The experimental results and numerical values were shown to be in good agreement. The sensor mass greatly affected the accuracy and precision of vibration response measurements in the composites structures. The smaller weight and area of the VIP accelerometer helped to minimize the decrease in accuracy and precision due to sensor mass. The effect of sensor location was found to be coupled with the effect of sensor mass and the bending mode shape. The sensor location did not affect the vibration response measurements when the sensor mass was minimized. Off-center horizontal sensor placement showed the possibility of measuring vibration torsion modes. The effect of delamination changed the bending mode shape of the composite structure, which corresponded to a change in natural frequency. The greatest effect of the delamination was seen at the bending mode node lines, where the bending mode shape was most significantly affected. The effect of delamination was also dependent on the location of the delamination and the composite structure type. The results of this study provided considerations for future research of an active structural health monitoring system of composite structures using dynamic response measurements. The considerations included sensor mass reduction, sensor placement at constraints and bond areas and the presence of damping material.

No description available.