Design and Demonstration of Automated Data Analysis Algorithms for Ultrasonic Inspection of Complex Composite Panels with Bonds

To address the data review burden and improve the reliability of the ultrasonic inspection of large composite structures, automated data analysis (ADA) algorithms have been developed to make calls on indications that satisfy the detection criteria and minimize false calls. The original design followed standard procedures for analyzing signals for time-of-flight indications and backwall amplitude dropout. However, certain complex panels with varying shape, ply drops and the presence of bonds can complicate this interpretation process. In this paper, enhancements to the automated data analysis algorithms are introduced to address these challenges. To estimate the thickness of the part and presence of bonds without prior information, an algorithm tracks potential backwall or bond-line signals, and evaluates a combination of spatial, amplitude, and time-of-flight metrics to identify bonded sections. Once part boundaries, thickness transitions and bonded regions are identified, feature extraction algorithms are applied to multiple sets of through-thickness and backwall C-scan images, for evaluation of both first layer through thickness and layers under bonds. ADA processing results are presented for a variety of complex test specimens with inserted materials and other test discontinuities. Lastly, enhancements to the ADA software interface are presented, which improve the software usability for final data review by the inspectors and support the certification process.