Ultrasonic air-coupled testing of square-shape CFRP composite rods by means of guided waves

In aerospace industry, one of the most important parts of gliders and motor-gliders is a lightweight longeron reinforcement made of carbon fibre reinforced plastics (CFRP) rods, known as Graphlite SM315 composite. During manufacturing, the rods as constructional elements are glued together in epoxy-filled matrix in order to build the arbitrary spar profile. The defects present in single rods such as breakage of fibres, multiple delaminations due to the lack of bonding between fibres and reduction in density affect essentially the strength and the fail-safety of the overall construction.The aim of the present work is to investigate the effects (transmission, reflection, scattering and mode conversion) of guided waves propagation along a square-shape CFRP rod in the case of contactless excitation/reception and interaction with region of multiple delaminations applying the numerical model and performing experiments.The square-shape CFRP composite rods possessing internal artificial delamination type defects have been investigated by numerical modelling and experiments employing the developed air-coupled technique (pitch-catch set-up) for cases of conventional transmission and advanced back-scattering configurations. Numerical predictions of guided wave interaction with a multiple delamination type defect in a CFRP composite rod have been made and the interaction mechanism explained. It is possible to conclude, that the actual sizes of the internal defects have been clearly detected using reception of the back-scattered waves over the edges of the defective regions only.

► The mechanism of guided waves interaction with delamination type defects has been investigated.
► The developed air-coupled techniques are easily applicable for inspection of moving CFRP rods.
► Two different testing configurations have been developed: transmission and back-scattering.
► Exploitation of back-scattered waves possesses higher losses but is more reliable.
► The length of the defects could be estimated with uncertainty of several millimetres.