Effective and Efficient Non-Destructive Testing of Large and Complex Shaped Aircraft Structures

The main aim of the research described within this thesis is to develop methodologies that enhance the defect detection capabilities of nondestructive testing (NDT) for the aircraft industry. Modem aircraft non-destructive testing requires the detection of small defects in large complex shaped components. Research has therefore focused on the limitations of ultrasonic, radioscopic and shearographic methods and the complimentary aspects associated with each method. The work has identified many parameters that have significant effect on successful defect detection and has developed methods for assessing NDT systems capabilities by noise analysis, excitation performance and error contributions attributed to the positioning of sensors. The work has resulted in 1. The demonstration that positional accuracy when ultrasonic testing has a significant effect on defect detection and a method to measure positional accuracy by evaluating the compensation required in a ten axis scanning system has revealed limitsio the achievable defect detection when using complex geometry scanning systems. 2. A method to reliably detect 15 micron voids in a diffusion bonded joint at ultrasonic frequencies of 20 MHz and above by optimising transducer excitation, focussing and normalisation. 3. A method of determining the minimum detectable ultrasonic attenuation variation by plotting the measuring error when calibrating the alignment of a ten axis scanning system. 4. A new formula for the calculation of the optimum magnification for digital radiography. The formula is applicable for focal spot sizes less than 0.1 mm. 5. A practical method of measuring the detection capabilities of a digital radiographic system by calculating the modulation transfer function and the noise power spectrum from a reference image. 6. The practical application of digital radiography to the inspection of super plastically formed ditThsion bonded titanium (SPFDB) and carbon fibre composite structure has been demonstrated but has also been supported by quantitative measurement of the imaging systems capabilities. 7. A method of integrating all the modules of the shearography system that provides significant improvement in the minimum defect detection capability for which a patent has been granted. 8. The matching of the applied stress to the data capture and processing during a shearographic inspection which again contributes significantly to the defect detection capability. 9. The testing and validation of the Parker and Salter [1999] temporal unwrapping and laser illumination work has led to the realisation that producing a pressure drop that would result in a linear change in surface deformation over time is difficult to achieve. 10. The defect detection capabilities achievable by thermal stressing during a shearographic inspection have been discovered by applying the pressure drop algorithms to a thermally stressed part. 11. The minimum surface displacement measurable by a shearography system and therefore the defect detection capabilities can be determined by analysing the signal to noise ratio of a transition from a black (poor reflecting surface) to white (good reflecting surface). The quantisation range for the signal to noise ratio is then used in the Hung [1982] formula to calculate the minimum displacement. Many of the research aspects contained within this thesis are cuffently being implemented within the production inspection process at BAE Samlesbury

ADVANCES IN IN-SITU SPECTROELECTROCHEMICAL FOURIER TRANSFORM INFRARED SPECTROSCOPY

The level of information provided by electrochemical measurements can be substantial as evident by the use of electrochemistry in varied disciplines spanning from materials research to cellular biochemistry. However, electrochemistry on its own does not provide direct information concerning redox induced changes in molecular structure. This information can only be elucidated by coupling spectroscopic and/or separation techniques with traditional electrochemical methodologies. In principle, infrared (IR) spectroelectrochemistry (SEC) is ideal for such studies but in practice coupling IR spectroscopy and electrochemistry are often experimentally incompatible. Since the inception of in-situ IR SEC techniques in the 1980’s, two competing methodologies (using either external- or internal- IR reflection geometries), were developed to deal with the two major challenges associated with IR SEC (strong infrared absorption of the electrolytes and weak analytical signals). The primary focus of this thesis is the successful advancement of IR SEC techniques through the implementation of synchrotron infrared radiation with ultramicroelectrodes (UMEs; electrode diameters < 25 µm) to study spectroelectrochemical processes on the microsecond time scale. Several examples using Surface Enhanced Infrared Absorption Spectroscopy (SEIRAS) are presented including the adsorption of dimethylaminopyridine (DMAP) on gold substrates and the proton-coupled electron-transfer (PCET) kinetics of electrochemically-active 1,4-benzoquinone terminated self-assembled monolayers (SAMs). These studies highlight the benefits of coupling electrochemistry and infrared spectroscopy. For instance, in-situ spectroscopic evidence shows that small amounts of DMAP’s conjugate acid (DMAPH+) adsorb on gold electrodes in acidic electrolytes and at negative potentials. This result was not forthcoming from previous electrochemical measurements and was only realized through in-situ SEIRAS. Finally, the largest contribution in advancing in-situ IR SEC methodologies was through the development of utilizing synchrotron infrared radiation on UMEs to study fast electrochemical processes. This work was technically very challenging and emphasized the interfacing of an electrochemical cell containing an UME with fast infrared data acquisition techniques (i.e. rapid scan and step-scan interferometry). The use of a prototypical electrochemical system, i.e. the mass-transport controlled reduction of ferricyanide, indicate that at short times the spectroscopic signal closely matches the electrochemical signal but at long time scales it deviates due to edge effects associated with the diffusion environment of the UME

Effective and efficient non-destructive testing of large and complex shaped aircraft structures

The main aim of the research described within this thesis is to develop methodologies that enhance the defect detection capabilities of nondestructive testing (NDT) for the aircraft industry. Modem aircraft non-destructive testing requires the detection of small defects in large complex shaped components. Research has therefore focused on the limitations of ultrasonic, radioscopic and shearographic methods and the complimentary aspects associated with each method. The work has identified many parameters that have significant effect on successful defect detection and has developed methods for assessing NDT systems capabilities by noise analysis, excitation performance and error contributions attributed to the positioning of sensors. The work has resulted in 1. The demonstration that positional accuracy when ultrasonic testing has a significant effect on defect detection and a method to measure positional accuracy by evaluating the compensation required in a ten axis scanning system has revealed limitsio the achievable defect detection when using complex geometry scanning systems. 2. A method to reliably detect 15 micron voids in a diffusion bonded joint at ultrasonic frequencies of 20 MHz and above by optimising transducer excitation, focussing and normalisation. 3. A method of determining the minimum detectable ultrasonic attenuation variation by plotting the measuring error when calibrating the alignment of a ten axis scanning system. 4. A new formula for the calculation of the optimum magnification for digital radiography. The formula is applicable for focal spot sizes less than 0.1 mm. 5. A practical method of measuring the detection capabilities of a digital radiographic system by calculating the modulation transfer function and the noise power spectrum from a reference image. 6. The practical application of digital radiography to the inspection of super plastically formed ditThsion bonded titanium (SPFDB) and carbon fibre composite structure has been demonstrated but has also been supported by quantitative measurement of the imaging systems capabilities. 7. A method of integrating all the modules of the shearography system that provides significant improvement in the minimum defect detection capability for which a patent has been granted. 8. The matching of the applied stress to the data capture and processing during a shearographic inspection which again contributes significantly to the defect detection capability. 9. The testing and validation of the Parker and Salter [1999] temporal unwrapping and laser illumination work has led to the realisation that producing a pressure drop that would result in a linear change in surface deformation over time is difficult to achieve. 10. The defect detection capabilities achievable by thermal stressing during a shearographic inspection have been discovered by applying the pressure drop algorithms to a thermally stressed part. 11. The minimum surface displacement measurable by a shearography system and therefore the defect detection capabilities can be determined by analysing the signal to noise ratio of a transition from a black (poor reflecting surface) to white (good reflecting surface). The quantisation range for the signal to noise ratio is then used in the Hung [1982] formula to calculate the minimum displacement. Many of the research aspects contained within this thesis are cuffently being implemented within the production inspection process at BAE Samlesbury.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

The Design of a Novel Tip Enhanced Near-field Scanning Probe Microscope for Ultra-High Resolution Optical Imaging

Traditional light microscopy suffers from the diffraction limit, which limits the spatial resolution to λ/2. The current trend in optical microscopy is the development of techniques to bypass the diffraction limit. Resolutions below 40 nm will make it possible to probe biological systems by imaging the interactions between single molecules and cell membranes. These resolutions will allow for the development of improved drug delivery mechanisms by increasing our understanding of how chemical communication within a cell occurs. The materials sciences would also benefit from these high resolutions. Nanomaterials can be analyzed with Raman spectroscopy for molecular and atomic bond information, or with fluorescence response to determine bulk optical properties with tens of nanometer resolution. Near-field optical microscopy is one of the current techniques, which allows for imaging at resolutions beyond the diffraction limit. Using a combination of a shear force microscope (SFM) and an inverted optical microscope, spectroscopic resolutions below 20 nm have been demonstrated. One technique, in particular, has been named tip enhanced near-field optical microscopy (TENOM). The key to this technique is the use of solid metal probes, which are illuminated in the far field by the excitation wavelength of interest. These probes are custom-designed using finite difference time domain (FDTD) modeling techniques, then fabricated with the use of a focused ion beam (FIB) microscope. The measure of the quality of probe design is based directly on the field enhancement obtainable. The greater the field enhancement of the probe, the more the ratio of near-field to far-field background contribution will increase. The elimination of the far-field signal by a decrease of illumination power will provide the best signal-to-noise ratio in the near-field images. Furthermore, a design that facilitates the delocalization of the near-field imaging from the far-field will be beneficial. Developed is a novel microscope design that employs two-photon non-linear excitation to allow the imaging of the fluorescence from almost any visible fluorophore at resolutions below 30 nm without changing filters or excitation wavelength. The ability of the microscope to image samples at atmospheric pressure, room temperature, and in solution makes it a very promising tool for the biological and materials science communities. The microscope demonstrates the ability to image topographical, optical, and electronic state information for single-molecule identification. A single computer, simple custom control circuits, field programmable gate array (FPGA) data acquisition, and a simplified custom optical system controls the microscope are thoroughly outlined and documented. This versatility enables the end user to custom-design experiments from confocal far-field single molecule imaging to high resolution scanning probe microscopy imaging. Presented are the current capabilities of the microscope, most importantly, high-resolution near-field images of J-aggregates with PIC dye. Single molecules of Rhodamine 6G dye and quantum dots imaged in the far-field are presented to demonstrate the sensitivity of the microscope. A comparison is made with the use of a mode-locked 50 fs pulsed laser source verses a continuous wave laser source on single molecules and J-aggregates in the near-field and far-field. Integration of an intensified CCD camera with a high-resolution monochromator allows for spectral information about the sample. The system will be disseminated as an open system design