Simulation of NDT methods for Additive Manufacturing of composites

Martins, Ana; Universidade Nova de Lisboa Unidade de Investigacao e Desenvolvimento em Engenharia Mecanica e Industrial; Portugal

Martins, A.P.; NOVA University Lisbon; Portugal
Carvalho, M.S.; NOVA University Lisbon; Portugal
Cardoso, J.B.; NOVA University Lisbon; Portugal
Santos, T.G.; University of Lisbon; Portugal

ID: ECNDT-0257-2018
Download: PDF
Session: Additive Manufacturing – various methods
Room: H1
Date: 2018-06-12
Time: 11:50 - 12:10

Significant progress in Additive Manufacturing technologies, initially intended for rapid prototyping, provided the ability to produce finished parts with complex geometries and reduced cost. In addition, recently developed 3D printers have the capability to yield composite structures by adding a reinforcement material to a polymeric matrix. This improved material may then be used for structural applications that demand for Non-Destructive Testing (NDT).
NDT techniques usually require great effort and large number of experiments to achieve appropriate probes design and testing conditions. However, the cost efficiency of the NDT methods can be achieved through appropriate numerical modelling. The numerical simulation assists the design of customized NDT probes and allows deeper physical phenomena insight. Moreover, with the validated numerical models, it is possible to optimize the test parameters and predict the outcomes of different procedures, being these the advantages of including computational models in NDT methods research.
This work presents the analyses of numerical simulations to support the NDT methods for continuous carbon fibre reinforced polymer parts produced by a fused deposition modelling technology. The possible defects of these specific components that can be detected by NDT are the voids, fibre discontinuities and delamination, for which is required to develop a multiparametric system for the inspection. Moreover, several case studies were selected for experimental testing and model simulations of thermography, ultrasound and eddy current techniques were performed. Available Finite Element Method (FEM) commercial codes ANSYS and LS-Dyna where used for simulation of the physical phenomena associated with these NDT techniques. Furthermore, with the concern to maintain a reasonable computational cost, some efforts are made to make the numerical models efficient.