Abstract: Systems, methods, and devices are provided for the creation of predictable and accurate defects in a fiber tow of an Automated Fiber Placement (AFP) process, with such artificial defects being useful to support calibration of an in situ inspection system used in the AFP process. Various embodiments include methods for creating such artificial defects that support calibration of an in situ inspection system of an AFP system or process. Various embodiments may also include a defect stencils for an AFP system or process.

Abstract: A method of detecting defects in a composite structure includes applying heat to a surface of a composite structure. Thermographic images or frames captured by a moving camera may be utilized to corm temporally aligned images that include temperature data (pixels) from a plurality of frames, wherein the pixels comprise data captured at a simple (uniform) time delay from the time at which heat was applied. The temporally aligned thermographic data for the surface region may include variations due to differences in thermal transients caused by defects in the composite structure. The variations in the thermographic data may be utilized to detect one or more defects in the composite structure.

Abstract: Systems, methods, and devices are provided for the creation of predictable and accurate defects in a fiber tow of an Automated Fiber Placement (AFP) process, with such artificial defects being useful to support calibration of an in situ inspection system used in the AFP process. Various embodiments include methods for creating such artificial defects that support calibration of an in situ inspection system of an AFP system or process. Various embodiments may also include a defect stencils for an AFP system or process.

Abstract: A method of detecting defects in a composite structure includes applying heat to a surface of a composite structure. Thermographic images or frames captured by a moving camera may be utilized to corm temporally aligned images that include temperature data (pixels) from a plurality of frames, wherein the pixels comprise data captured at a simple (uniform) time delay from the time at which heat was applied. The temporally aligned thermographic data for the surface region may include variations due to differences in thermal transients caused by defects in the composite structure. The variations in the thermographic data may be utilized to detect one or more defects in the composite structure.

Abstract: A method of detecting defects in a composite structure includes applying heat to a surface of a composite structure. Thermographic images or frames captured by a moving camera may be utilized to form temporally aligned images that include temperature data (pixels) from a plurality of frames, wherein the (pixels) comprise data captured at a simple (uniform) time delay from the time at which heat was applied. The temporally aligned thermographic data for the surface region may include variations due to differences in thermal transients caused by defects in the composite structure. The variations in the thermographic data may be utilized to detect one or more defects in the composite structure.

Abstract: Various embodiment methods to reliably and repeatedly replicate delaminations/disbonds and/or porosity defects in specimens/structures may include constructing the specimens/structures such that aerogel sheets and/or aerogel powders are placed or deposited in selected delamination/disbonding and/or porosity locations in the specimen/structure before the specimen/structure is cured. In various embodiments, the specimens/structures may be composites and/or bonded structures and the structures may be flat or curved. The aerogel sheets and/or aerogel powders may mimic delamination/disbonding and/or porosity defects in the cured specimens/structures. The cured specimens/structures including the replicated aerogel sheets and/or aerogel powders may be used for nondestructive inspection or other measurements, such as POD studies.

Abstract: A method of detecting defects in a composite structure includes applying heat to a surface of a composite structure. Thermographic images or frames captured by a moving camera may be utilized to corm temporally aligned images that include temperature data (pixals) from a plurality of frames, wherein the pixals comprise data captured at a simple (uniform) time delay from the time at which heat was applied. The temporally aligned thermographic data for the surface region may include variations due to differences in thermal transients caused by defects in the composite structure. The variations in the thermographic data may be utilized to detect one or more defects in the composite structure.

Abstract: Various embodiment methods to reliably and repeatedly replicate delaminations/disbonds and/or porosity defects in specimens/structures may include constructing the specimens/structures such that aerogel sheets and/or aerogel powders are placed or deposited in selected delamination/disbonding and/or porosity locations in the specimen/structure before the specimen/structure is cured. In various embodiments, the specimens/structures may be composites and/or bonded structures and the structures may be flat or curved. The aerogel sheets and/or aerogel powders may mimic delamination/disbonding and/or porosity defects in the cured specimens/structures. The cured specimens/structures including the replicated aerogel sheets and/or aerogel powders may be used for nondestructive inspection or other measurements, such as POD studies.