1、Designation: E 2580 07Standard Practice forUltrasonic Testing of Flat Panel Composites and SandwichCore Materials Used in Aerospace Applications1This standard is issued under the fixed designation E 2580; the number immediately following the designation indicates the year oforiginal adoption or, in
2、the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This practice establishes two procedures for ultrasonictesting (UT) of flat panel c
3、omposites and flat sandwich corepanels (parallel surfaces). Typical as-fabricated lay-ups includeuniaxial, cross ply and angle ply laminates; as well as honey-comb sandwich core materials. These procedures can be usedthroughout the life cycle of the materials; product and processdesign optimization,
4、 on line process control, after manufactureinspection, and in service inspection. Contact methods such asangle-beam techniques using shear waves, or surface-beamtechniques using Lamb waves, are not discussed.1.2 Ultrasonic testing is a common sub surface method fordetection of laminar oriented disco
5、ntinuities. Two techniquescan be considered based on panel surface accessibility; pulseecho for one sided and through transmission (bubblers/squirters) for two sided. As used in this practice, both requirethe use of a pulsed straight-beam ultrasonic longitudinal wavefollowed by observing indications
6、 of either the reflected(pulse-echo) or received (through transmission) wave. Thegeneral types of anomalies detected by both techniques includeforeign materials, delamination, disbond/un-bond, fiber de-bonding, inclusions, porosity, and voids.1.3 This practice provides two ultrasonic test procedures
7、.Each has its own merits and requirements for inspection andshall be selected as agreed upon in a contractual document.1.3.1 Test Procedure A, Pulse Echo (non-contacting andcontacting), is at a minimum a single transducer transmittingand receiving a longitudinal wave in the range of 0.5 to 20MHz (se
8、e Fig. 1). This procedure requires access to only oneside of the specimen. This procedure can be conducted byautomated or manual means. Automated and manual testresults may be imaged or recorded.1.3.2 Test Procedure B, Through Transmission, is a combi-nation of two transducers. One transmits a longi
9、tudinal waveand the other receives the longitudinal wave in the range of 0.5MHz to 20 MHz (see Fig. 2). This procedure requires access toboth sides of the specimen. This procedure is automated andthe examination results are recorded.1.4 This practice does not specify accept-reject criteria.1.5 This
10、standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2
11、.1 ASTM Standards:2C 274 Terminology of Structural Sandwich ConstructionsD 3878 Terminology for Composite MaterialsD 5687/D 5687M Guide for Preparation of Flat CompositePanels with Processing Guidelines for Specimen Prepara-tionE 114 Practice for Ultrasonic Pulse-Echo Straight-BeamExamination by the
12、 Contact MethodE 543 Specification for Agencies Performing Nondestruc-tive TestingE 1309 Guide for Identification of Fiber-ReinforcedPolymer-Matrix Composite Materials in DatabasesE 1316 Terminology for Nondestructive ExaminationsE 1434 Guide for Recording Mechanical Test Data of Fiber-Reinforced Co
13、mposite Materials in DatabasesE 1471 Guide for Identification of Fibers, Fillers, and CoreMaterials in Computerized Material Property Databases2.2 SAE Standards:3ARP 5605 Solid Composite Laminate NDI Reference Stan-dards, Issued 2001-09ARP 5606 Composite Honeycomb NDI Reference Stan-dards, Issued 20
14、01-092.3 AIA Standard:4NAS-410 Nondestructive Testing Certification of Personnel2.4 ASNT Standards:51This practice is under the jurisdiction of ASTM Committee E07 on Nonde-structive Testing and is the direct responsibility of Subcommittee E07.06 onUltrasonic Method.Current edition approved July 1, 2
15、007. Published July 2007.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from Society of Automotiv
16、e Engineers (SAE), 400 CommonwealthDr., Warrendale, PA 15096-0001, http:/www.sae.org.4Available from Aerospace Industries Association of America, Inc. (AIA), 1000Wilson Blvd., Suite 1700,Arlington, VA22209-3928, http:/www.aia-aerospace.org.5Available fromAmerican Society for Nondestructive Testing (
17、ASNT), P.O. Box28518, 1711 Arlingate Ln., Columbus, OH 43228-0518, http:/www.asnt.org.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.SNT-TC-1A Recommended Practice for Personnel Qualifi-cation and Certification in Nondestructive Tes
18、tingANSI/ASNT CP-189 Standard for Qualification and Certi-fication or Nondestructive Testing Personnel3. Terminology3.1 DefinitionsTerminology in accordance with Termi-nologies C 274, E 1316, and D 3878 shall be used whereapplicable.3.2 Definitions of Terms Specific to This Standard:3.2.1 flat panel
19、 composite, nany fiber reinforced compos-ite lay-up consisting of laminate (plies) with one or moreorientations with respect to some reference direction that areconsolidated by press or autoclave to yield a two-dimensionally flat article of finite thickness.3.2.2 sandwich core material, na structura
20、l panel made upof two relatively thin outer skins of composite laminate orother material, such as metal or wood, separated by and bondedto a relatively thick lightweight inner core such as honeycomb,FIG. 1 Test Procedure A, Pulse Echo Apparatus Set-upFIG. 2 Test Procedure B, Through Transmission App
21、aratus Set-upE2580072open and close cell foam, wave formed material, bondedcomposite tubes, or naturally occurring material such as balsawood.4. Summary of Practice4.1 This practice describes two procedures for detectinganomalies in flat panel composite and flat sandwich core panelsusing ultrasonic
22、longitudinal waves coupled by either contact(Procedure A) or bubbler/squirter (Procedure B). Equipment,reference blocks, examination and evaluation procedures, anddocumentation are described in detail.5. Significance and Use5.1 This practice is intended primarily for the testing of flatpanel composi
23、tes and sandwich core panels to an acceptancecriteria most typically specified in a purchase order or othercontractual document.5.2 Basis of ApplicationThere are areas in this practicethat require agreement between the cognizant engineeringorganization and the supplier, or specific direction from th
24、ecognizant engineering organization.6. Equipment and Materials6.1 Equipment6.1.1 OperationTest equipment shall be capable of pro-viding uniform, repeatable, and controlled operation.6.1.2 Electronic EquipmentThe electronic equipmentshould be capable of producing and processing electronicsignals at f
25、requencies in the range of search unit frequenciesbeing used.6.1.3 Search Unit(s)The search unit(s) selected should becompatible with the electronic equipment being used and withthe material to be inspected. The search unit should match theintended squirter(s) or contact. Only straight-beam (longitu
26、di-nal) search units, with flat or focused acoustic lenses, should beused.6.1.4 AlarmThe alarm or threshold level should be ad-justable to allow triggering at any commonly required level ofindication amplitude. Alarms are not required on systems thatrecord amplitude recordings.6.1.5 Alarm Gate Synch
27、ronizationIn the pulse echo modeensure that the alarm gate tracks the inspection area. The gateshould lock on the first interface pulse from the test piece ratherthan on the initial pulse from the system. In the throughtransmission mode the alarm gate should be wide enough tocover any negative or po
28、sitive movement (left to right) in thehorizontal plane.6.1.6 Manipulating Equipment should be provided to ad-equately support the search tube(s) and allow angular adjust-ment in two mutually perpendicular planes. The search unitmanipulator shall be capable of providing the adjustmentsnecessary to pr
29、operly position the search unit during testing.The scanning and indexing apparatus should have sufficientstructural rigidity to provide support for the manipulator andshould allow smooth, accurate positioning of the search unit.The scanning apparatus should be sufficiently rigid to keepsearch unit b
30、acklash to within tolerances as specified in thecontractual agreement.6.1.7 Tank or Gantry SystemThe tank or gantry systemshould permit accurate positioning of the search unit, referencestandards, and part or material to be examined.6.1.8 SquirterThe squirter equipment shall be capable ofsupplying a
31、 laminar flow of coupling fluid from the transducerto the part being tested at all angles used.6.1.9 Scan-RecordThe recording shall not exhibit back-lash or hysteresis that would hinder detection or evaluation ofdiscontinuities.6.1.10 Composite Reference BlocksFor the applicabletesting system the re
32、sponses from reference block and partshall be similar to the extent that standardization of the testingsystem can be accomplished and demonstrated to provide aknown and acceptable detection level in the part. Referenceblocks contain either structural anomalies or foreign inclu-sions. Structural anom
33、alies are those that are known to bepossible during the life cycle of the material. Debonding duringmanufacturing or delamination during in-service may be rep-resented by the block. Foreign inclusions most commonlyencountered during manufacturing are used in the referenceblocks.6.1.11 Transfer Cutou
34、tsWhen non-contact through-transmission is used transfer cutouts may be used in lieu ofreference blocks when agreed upon contractually. The size ofthe transfer cutouts shall be agreed contractually. The transfercutouts must provide sufficient attenuation to simulate voids orunbonds in the part. Tran
35、sfer cutouts shall be attached to thepart and be placed to cover changes in part configuration andalignment.6.2 Materials:6.2.1 Flat Panel SpecimensProcessing guidelines thatfacilitate fabrication of flat panel composite specimens madefrom unidirectional tape or using orthogonal weave patterns arefo
36、und in Guide D 5687/D 5687M. For specimen preparationusing other processing techniques, for example, pultrusion,filament winding and resin transfer molding, processing guide-lines are not available and shall be agreed upon by the usingparties.6.2.2 Sandwich Core SpecimensProcessing guidelines forfab
37、rication of sandwich construction specimens are diverse andshall be agreed upon by the using parties.6.2.3 Transfer CutoutsTransfer cutouts shall be made oftwo layers of lead foil tape cut to size.6.2.4 CouplantsImmersion and contact couplants shallprovide intimate coupling between search unit and p
38、art; shallbe compatible with the part; and shall be easily removed fromthe part using an applicable cleaning process.7. General Requirements7.1 In-process testing of flat panel composite or honeycombstructure shall be conducted using automated equipment ca-pable of electronically recording the test
39、output or manualcontact during indication evaluation. There shall be a directcorrelation of the electronic recording and the tested specimen.Transducer frequency shall be determined by the materialsapparent attenuation and the required acceptance criteria. Scanincrement shall be set to provide three
40、 ultrasonic signalviolations from the standard at the specified threshold level.E25800737.2 If required by contract, evaluation of the agency per-forming testing shall be in accordance with Practice E 543.7.3 In-service testing shall be conducted using manualcontact techniques, these tests are for t
41、he determination ofsuspected areas of damage. Testing shall be conducted using areference standard. This reference standard shall be of the sameconfiguration as the test specimen or as agreed upon contrac-tually. This reference standard shall be acoustically similar andcontain simulated or actual di
42、scontinuities.7.4 In-process testing of flat panel composites shall be forthe detection of foreign materials, delaminations, voids andporosity. In-process testing of honeycomb structures shall befor the detection of non-bonds between the face sheets andcore. In-service testing of flat panel composit
43、es shall be for thedetection of damage such as delaminations. In-service testingof honeycomb structure shall be for unbond between the facesheet and core.7.5 Material ConditionPerform ultrasonic testing of partsor materials that possess a clean and smooth surface.7.6 CoverageIn all examinations, per
44、form scanning tolocate discontinuities that are oriented parallel with the entrysurface. The index increment shall be such that the targetsimulated anomaly registers three times at a contractuallyagreed upon threshold.7.7 Ultrasonic FrequencyFor a particular test select thefrequency based on the mat
45、erial being inspected and of theanticipated type of discontinuities.7.8 EvaluationEvaluate each discontinuity to determineits type, size, location and conformance to the applicableaccept/reject criteria. Specific discontinuity evaluation proce-dures shall be agreed upon contractually.7.9 Technique R
46、ecordFor each part inspected, a techniquerecord shall be completed for each discontinuity detection scanand indication evaluation set-up used. The technique recordshall identify the part, the area or zone, or bond-line of the partbeing inspected, the inspector, the inspection procedure, andthe equip
47、ment used. The record shall include cross-sectionalsketches as necessary to show part coverage. The techniquerecord shall note instrument control settings such that the testcan be repeated.TEST PROCEDURES8. Procedure A8.1 Test procedure A (Pulse-Echo) is a single transducertransmitting and receiving
48、 a longitudinal wave in the range of0.5 MHz to 20 MHz (see Fig. 1). This procedure can beautomated or manual. The test results may be recorded. Thisprocedure requires access to one side of the specimen.8.1.1 Select the ultrasonic transducer based on the specificrequirements of the material, disconti
49、nuity size, resolution, andlife cycle requirements.8.1.2 Select the reference block based on the objective ofthe test. Step wedge blocks may be useful for ply count andde-bond or delamination. Flat bottom holes may be useful todetermine the size of a given discontinuity at a known ply ormaterial thickness.8.1.3 Select the frequency based on the acoustic propertiesof the material and the testing sensitivity required. Thefrequency should provide a discontinuity to parent materialsignal ratio of 3 to 1.8.2 Pulse-Echo Testing Application8.2.1 Non-Contact Testing8
