Abstract: Disclosed herein is a calibration panel that models acoustic properties of defects in vehicle components made of composite materials. The calibration panel includes a body formed by additive manufacturing from a first digital material having an acoustic property selected to approximate an acoustic property of a composite material and an insert embedded within the body. The insert is formed of at least a second digital material having an acoustic property selected to approximate an acoustic property of a defect within the composite material. Also disclosed is a method for manufacturing vehicle components that are non-destructive evaluation (NDE)-compliant. The method includes receiving a proposed design of a component, manufacturing the calibration panel, and testing the calibration panel to determine if the insert is detectable using acoustic emission testing. The method also includes rejecting, in response to a not-detectable status of the insert, the proposed design of the component.

Abstract: Disclosed herein is a detection assembly for detecting kissing bonds in a bonded joint of a part. The detection assembly comprises an electromagnetic shockwave generator that is configured to generate an electromagnetic shockwave through a target portion of the bonded joint. The electromagnetic shockwave has an intensity sufficient to induce a separation of a kissing bond in the target portion of the bonded joint and insufficient to induce a separation of a healthy bond, adjacent the kissing bond, in the target portion. The detection assembly also comprises an ultrasonic sensor that is configured to generate a transmitted ultrasonic pulse, direct the transmitted ultrasonic pulse into the target portion of the bonded joint, and receive a received ultrasonic pulse from the target portion of the bonded joint in response to the electromagnetic shockwave generator generating the electromagnetic shockwave through the target portion of the bonded joint.

Abstract: Disclosed herein is a calibration panel that models acoustic properties of defects in vehicle components made of composite materials. The calibration panel includes a body formed by additive manufacturing from a first digital material having an acoustic property selected to approximate an acoustic property of a composite material and an insert embedded within the body. The insert is formed of at least a second digital material having an acoustic property selected to approximate an acoustic property of a defect within the composite material. Also disclosed is a method for manufacturing vehicle components that are non-destructive evaluation (NDE)-compliant. The method includes receiving a proposed design of a component, manufacturing the calibration panel, and testing the calibration panel to determine if the insert is detectable using acoustic emission testing. The method also includes rejecting, in response to a not-detectable status of the insert, the proposed design of the component.

Abstract: Disclosed herein is a calibration panel that models acoustic properties of defects in vehicle components made of composite materials. The calibration panel includes a body formed by additive manufacturing from a first digital material having an acoustic property selected to approximate an acoustic property of a composite material and an insert embedded within the body. The insert is formed of at least a second digital material having an acoustic property selected to approximate an acoustic property of a defect within the composite material. Also disclosed is a method for manufacturing vehicle components that are non-destructive evaluation (NDE)-compliant. The method includes receiving a proposed design of a component, manufacturing the calibration panel, and testing the calibration panel to determine if the insert is detectable using acoustic emission testing. The method also includes rejecting, in response to a not-detectable status of the insert, the proposed design of the component.

Abstract: Noise present in ultrasonic tests applied by an ultrasonic test system to test objects, e.g., production parts, is reduced to provide more accurate results and to reduce waste, e.g., by reducing the number of test objects inaccurately identified as faulty. To that end, a noise signature is obtained for an ultrasonic test applied by the ultrasonic test system to a known object having the same dimensions and the same material composition as the test objects. The noise present in the output of the ultrasonic test applied by the ultrasonic test system to one or more of the test objects is then reduced responsive to the obtained noise signature to improve the accuracy of the ultrasonic test.

Abstract: Disclosed herein is a detection assembly for detecting kissing bonds in a bonded joint of a part. The detection assembly comprises an electromagnetic shockwave generator that is configured to generate an electromagnetic shockwave through a target portion of the bonded joint. The electromagnetic shockwave has an intensity sufficient to induce a separation of a kissing bond in the target portion of the bonded joint and insufficient to induce a separation of a healthy bond, adjacent the kissing bond, in the target portion. The detection assembly also comprises an ultrasonic sensor that is configured to generate a transmitted ultrasonic pulse, direct the transmitted ultrasonic pulse into the target portion of the bonded joint, and receive a received ultrasonic pulse from the target portion of the bonded joint in response to the electromagnetic shockwave generator generating the electromagnetic shockwave through the target portion of the bonded joint.

Abstract: Disclosed herein is a calibration panel that models acoustic properties of defects in vehicle components made of composite materials. The calibration panel includes a body formed by additive manufacturing from a first digital material having an acoustic property selected to approximate an acoustic property of a composite material and an insert embedded within the body. The insert is formed of at least a second digital material having an acoustic property selected to approximate an acoustic property of a defect within the composite material. Also disclosed is a method for manufacturing vehicle components that are non-destructive evaluation (NDE)-compliant. The method includes receiving a proposed design of a component, manufacturing the calibration panel, and testing the calibration panel to determine if the insert is detectable using acoustic emission testing. The method also includes rejecting, in response to a not-detectable status of the insert, the proposed design of the component.

Abstract: A laser shearography testing system for non-destructively testing a component includes a component heating sub-system coupled to the component. The component heating sub-system excites the component into a loaded state by passing an electric current through the component. A resistivity of the component causes the component to internally and uniformly heat as the electric current passes through the component.

Abstract: A laser shearography testing system for non-destructively testing a component includes a component heating sub-system coupled to the component. The component heating sub-system excites the component into a loaded state by passing an electric current through the component. A resistivity of the component causes the component to internally and uniformly heat as the electric current passes through the component.

Abstract: Noise present in ultrasonic tests applied by an ultrasonic test system to test objects, e.g., production parts, is reduced to provide more accurate results and to reduce waste, e.g., by reducing the number of test objects inaccurately identified as faulty. To that end, a noise signature is obtained for an ultrasonic test applied by the ultrasonic test system to a known object having the same dimensions and the same material composition as the test objects. The noise present in the output of the ultrasonic test applied by the ultrasonic test system to one or more of the test objects is then reduced responsive to the obtained noise signature to improve the accuracy of the ultrasonic test.