| Citation: |
XIAO Kedi, MA Zhaoqing, GAO Chenjia, et al. Air-coupled ultrasonic testing and analysis on delamination defect of low-density thermal protection and insulation material[J]. Acta Materiae Compositae Sinica, 2025, 42(2): 835-844. DOI: 10.13801/j.cnki.fhclxb.20240427.002
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The low-density thermal protection and insulation material is an important constituent material on aerospace craft thermal protection system. The material is low density, high porosity, and low thermal conductivity, with lightweight and excellent thermal protection and insulation performance. However, the material and its microscopic structure characteristics cause difficulties on non-destructive testing on the internal defects. The regular ultrasonic transmission testing is unsuitable, and the infrared testing is less effective. To detect the delamination defect of low-density thermal protection and insulation material, which is composed of quartz needled fabric and phenolic resin, the research on air-coupled ultrasonic testing is carried out. The microstructure of the material was analyzed by X-ray Micro-CT detection. The relationship between delamination defect sound pressure transmittance and air gap thickness was estimated. The material specimens with densities of 0.4, 0.5, 0.6, 0.7 g/cm3 were made. The research of air-coupled ultrasonic testing on the specimens with probe frequencies of 50, 140, 200 kHz was performed. The result shows, the air-coupled ultrasonic testing is effective on delamination defect detection of low-density thermal protection and insulation material. The suitable detection frequency and detectability are both related to the material density and the material homogeneity. When the material thickness is 30 mm, the delamination defect air gap thickness is 0.3 mm, the probe frequency is 50 kHz, and the material density is within 0.4-0.7 g/cm3, the delamination defect with diameter greater than 30 mm can be detected.
The low-density thermal protection and insulation material is an important constituent material on aerospace craft thermal protection system. The material is low density, high porosity, and low thermal conductivity, with lightweight and excellent thermal protection and insulation performance. However, the material and its microscopic structure characteristics cause difficulties on non-destructive testing on the internal defects. The regular ultrasonic transmission testing is unsuitable, and the infrared testing is less effective. To detect the delamination defect of low-density thermal protection and insulation material, which is composed of quartz needled fabric and phenolic resin, the research on air-coupled ultrasonic testing is carried out. The applicability of the testing is also discussed.
The X-ray micro-CT detection was performed to analyze microstructural features of the material and morphology of the delamination defect. With analysis of ultrasonic wave propagation paths, the ultrasonic penetration wave amplitude decibel difference between good area and defect area was derived. The variation of decibel difference with delamination defect thickness was estimated. Based on the material features, the specimens were made. Each specimen was made by bonding two materials together. The artificial defect was processed in either of the bonded surface with a round flute with depth of 0.3 mm. Four specimens with densities of 0.4, 0.5, 0.6, 0.7 g/cm were made. The research of air-coupled ultrasonic testing on the four specimens with probe frequencies of 50, 140, 200 kHz was performed.
①The fiber cloth and mesh inside the low-density material have fluctuations, such that the material density is not the same in different positions. This microstructural feature causes scattering and damping of the ultrasonic wave when the wave is propagating in the material. The delamination defect exists in the low-density material, and the maximum air gap thickness is about 0.25~0.3 mm. ②Define the product of ultrasonic frequency and air gap thickness as the frequency-thickness product . The sound pressure transmittance of the delamination defect is related to the frequency-thickness product. In low-density materials, when the frequency-thickness product is between 10~0.1 MHz·mm, the sound pressure transmittance is between 0%~100%. In this situation, parts of the sound wave pass through the air gap. With increase of frequency-thickness product, the sound pressure transmittance decreases. Considering the penetration wave amplitude fluctuation, which is caused by the inhomogeneity of low-density materials, the air gap thicknesses of the delamination defect at 50 kHz and 200 kHz are estimated to be 0.2 mm and 0.05 mm, respectively. ③The air-coupled ultrasonic testing result shows, the porosity of the material with density of 0.4 g/cm is high, and only frequency of 50 kHz is applicable. The defects with diameter of 30 mm and above can be detected. The homogeneity of the material with density of 0.5 g/cm is good. The defects with diameter of 20 mm and above can be detected at frequencies of 140 kHz and 200 kHz, and defects with diameter of 30 mm and above can be detected at frequency of 50 kHz. Frequencies of 50, 140, and 200 kHz is all suitable for materials with densities of 0.6 g/cm and 0.7 g/cm. The defects with diameter of 30 mm and above can be detected. ④In scan images with frequencies of 200 kHz and 140 kHz, some cloud-like patterns are visible in the good areas. Some samples of these areas were detected by Micro-CT. It was found that the patterns corresponded to the irregular spatial aggregation of small gaps in the material.
The air-coupled ultrasonic testing is effective on delamination defect detection of low-density thermal protection and insulation material. The suitable detection frequency and detectability are both related to the material density and the material homogeneity. When the material thickness is 30 mm, the delamination defect air gap thickness is 0.3 mm, the probe frequency is 50 kHz, and the material density is within 0.4~0.7 g/cm, the delamination defect with diameter greater than 30 mm can be detected. The results of this study are of great significance for analyzing the internal structure and defects of low-density thermal protection and insulation material, and guiding the research of air-coupled ultrasonic testing.
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