M1-M6 Progress

Project progress, October 2015 (M6)

During the first semester, the ComBoNDT partners focused on the definition of real-life application scenarios and accordingly decided on the properties of the samples and contaminants which need to be examined. Real-life challenges provided by the industrial partners confirm the significance of the ComBoNDT research and the necessity of introducing quality assurance concepts for adhesive bonding. These challenges cover both areas of Manufacturing and Repair and are examined as test-cases. The various materials, processes and parameters related to these applications (e.g. CFRP materials, types of adhesives used, surface preparations, etc.) are thoroughly explored and a list of specifications was developed towards the development of test coupons.

The first samples are already produced and, following a series of preparation processes, these are now ready to be distributed to the respective partners for conducting their experiments. Sample preparation include activities such as surface pre-treatment, cutting of CFRP samples, surface conditioning, bonding of samples, as well as a series of mechanical tests.

Activities on the validation of ENDT techniques and technology assessment current cover the examination of Technology Readiness Levels (TRL) 3 (“Analytical and experimental critical function and/or characteristic proof-of-concept”) and 4 (“Component/subsystem validation in laboratory environment”), while TRLs 5 (“System/subsystem/component validation in relevant environment”) and 6 (“System/subsystem model or prototyping demonstration in a relevant end-to-end environment”) will be examined later in the project.

Activities regarding the development of ENDT for surface quality assurance have just started and partners are considering the various surface inspection methods to be explored, matured and optimized within ComBoNDT, including Laser Induced Breakdown Spectroscopy (LIBS), Optically Simulated Electron Emission (OSEE), Full-Field Vibrometry, Electronic Nose (E-NOSE), and Aerosol Wetting Test. In a similar way, partners examine the processes to be used for the quality assurance of adhesive bonding, such as Shock Wave Adhesion Test, Electromechanical Impedance, Linear and non-linear ultrasound and Magnetostrictive sensors. All the aforementioned techniques have are already applied in various industrial applications, while they have also been examined within the framework of previous research projects such as ENCOMB (“Extended Non-Destructive Testing of Composite Bonds”), INDUCER (“Induction Heating and Health Monitoring Solutions for Smart Aircraft Maintenance using Adapted Composite Patches”) and MAGNASENSE (“Magnetostrictive sensor applications for self-sensing of bonded composite repairs”).

Lead by: GMI. Read the WP1 description here

Within ComBoNDT Task 1.1 the test scenarios to be investigated, the sample preparation requirements and the sample measurements to be performed have been identified and described in detail, according to a combination of parameters, such as the field of application (manufacturing or repair), the sample characteristics, the applied NDT methods, the surface state etc.

Within Deliverable 1.1, all these parameters and decisions taken according to input received by competent partners are addressed, while the specimen’s definition and fabrication process, to ensure the availability of samples (namely test coupons and pilot samples) with unchanged properties throughout the entire duration of the project for all partners, are described in detail. As a result, a synthetic table, including the list of examined contaminants, combined with the Surface Quality Assurance / Adhesive Bondline Quality Assurance methods to be employed, as well as with reference to production / repair activities has been prepared. To assist in the monitoring of the sample preparation and testing process, a codification system for specimens has been defined, while the deliverable concludes with an exhaustive table of specimens’ size, configuration, contamination levels and associated mechanical tests.

Lead by: AGI-G. Read the WP1 description here

WP6 is dealing with the validation of relevant methods for quality evaluation of bondings. Therefore, the Technology Readiness Level (TRL) of each technology should be evaluated at the beginning of the project and at the end. In this way, the progress of each method could be monitored and assessed. With the activities of WP6.1. the TRL catalogue was developed based on input from the partners and literature, as this is summarized in the table below. For ComBoNDT, TRL levels 3 to 6 are of interest since they describe the criteria for research and from there the path to product.

TRL Description Hardware Description Software Description Exit Criteria
3 Analytical and/or experimental critical function or characteristic proof-of-concept Analytical studies place the technology in an appropriate context and laboratory demonstrations, modeling and simulation validate analytical prediction Development of limited functionality to validate critical properties and predictions using non-integrated software components Documented analytical/experimental results validating predictions of key parameters
4 Component or breadboard validation in laboratory A low fidelity system/component breadboard is built and operated to demonstrate basic functionality and critical test environments and associated performance predictions are defined relative to the final operating environment Key, functionally critical,software components are integrated, and functionally validated, to establish inter-operability and begin architecture development. Relevant environments defined and performance in this environment predicted Documented test performance demonstrating agreement with analytical predictions. Documented definition of relevant environment
5 Technology validated in relevant environment A mid-level fidelity system/component brassboard is built and operated to demonstrate overall performance in a simulated operational environment with realistic support elements that demonstrates overall performance in critical areas. Performance predictions are made for subsequent development phases End to End Software elements implemented and interfaced with existing systems conforming to target environment, including the target to software environment. End to End Software System, Tested in Relevant Environment, Meets Predicted Performance. Operational Environment Performance Predicted Documented test performance demonstrating agreement with analytical predictions. Documented definition of scaling requirements
6 Technology demonstrated in relevant environment A high-fidelity system/component prototype that adequately addresses all critical scaling issues is built and operated in a relevant environment to demonstrate operations under critical environmental conditions Prototype software partially integrated with existing hardware/software systems and demonstrated on full scale realistic problems Documented test performance demonstrating agreement with analytical predictions

WP6.2 has started after the WP6.1. definitions were finished. The partners are now asked to perform the TRL review for their technologies at the beginning of the project.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636494.

This project is endorsed by the European Aeronautics Science Network - EASN.

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