Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000. Dennis Roach, Tom Rice, Stephen Neidigk, Randy Duvall, Josh Paquette Sandia National Labs Results from WINDIE Experiment to Characterize Inspection Methods for Wind Blades and Use of Probability of Detection Studies to Quantify NDI Performance
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Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy’s National Nuclear Security Administration
under contract DE-AC04-94AL85000.
Dennis Roach, Tom Rice, Stephen Neidigk, Randy Duvall, Josh Paquette
Sandia National Labs
Results from WINDIE Experiment to Characterize Inspection Methods for Wind Blades and Use of Probability
of Detection Studies to Quantify NDI Performance
Results from WINDIE Experiment to Characterize Inspection Methods for Wind Blades and Use of Probability
Different Flaw Types Engineered into NDI Feedback Specimens
Different Flaw Types Engineered into NDI Feedback Specimens
Glass Beads Grease Pillow InsertMold Release
Voids in bond joint
Glass beadsIn bond joint
Dry fabric areasWaviness produced by pre-cured
resin rods
Pull tabs inbond joint
Materials inserted into multiple layers
Spar Cap and Shear WebNDI Feedback Specimen No. 2
Spar Cap and Shear WebNDI Feedback Specimen No. 2
1.01"
0.34"
1.35"
0.68"
0.67"
1.35"
0.34"
1.01"1.35"
USED VECTORPLY ELT 5500 24 PLIES OF MATERIAL (UNIAXIAL FIBER)
2.000"1.000"
2.000"
.40" (10mm) BONDLINE
INSPECTION SIDE
PERCENTAGE OF FULLTHICKNESS AT BONDLINE(.100" SKIN AND .400" BONDTHICKNESS)
25% (OF FULL THICKNESS)
50% (OF FULL THICKNESS)
75% (OF FULL THICKNESS)FLAT BOTTOM HOLE (FBH)
PILLOW INSERT
EXAMPLES OF VARIOUS FLAW DEPTHS IN SPAR CAP SECTION
INSPECTION SURFACE
NDI REFERENCE STANDARD 2 FABRICATION DRAWING SPAR CAP AND SHEAR WEB BLADE SCHEMATIC
(DISBONDS IN ADHESIVE)PULL TABS
(DELAMS) (DELAMS) (BASED ON 24 PLIES OF UNIAXIAL MAT'L)(DISBONDS IN ADHESIVE)
25%(.125" MR)
50%(.25" MR)
1.00" DIA
2.00" DIA
SHEAR WEB
ADHESIVE
FLAT BOTTOM HOLES
1.00" (25mm) FOAM CORE
INTERFACE 2
INTERFACE 1
INTERFACE 1
25%(B/W PLIES 18 & 19)
75%(B/W PLIES 6 & 7)
75%(.375" MR)
4 PLY PILLOW INSERTSFLAT BOTTOM HOLES
25% (B/W PLIES18 & 19)
50% (B/W PLIES12 & 13)
75% (B/W PLIES6 & 7)
25% (.34" MR)50% (.68" MR)75% (1.01" MR)
2.00" DIA
.50" DIA
1.00" DIA1.50" DIA
1.50" DIA 1.00" DIA
.50" DIA
2.00" DIA
2.00" DIA
.50" DIA
1.00" DIA1.50" DIA
1.50" DIA 1.00" DIA
.50" DIA
2.00" DIA
2.00" DIA
1.50" DIA
1.00" DIA
.50" DIA
.50" DIA
1.00" DIA
1.50" DIA
2.00" DIA
18.00"
~1.35" (34mm) UNIAXIAL (SPANWISE)
30.00"
__(+45, +45)2 PLIES OF DOUBLE BIAS (DB)
2 PLIES OF DOUBLE BIAS (DB)
11-30-10
MR = MATERIAL REMAINING
PLY NO. 1 OF SPAR CAP
2 PLIES OF DOUBLE BIAS (DB)
(+45, +45)_ _
__(+45, +45)
(NOTE: IF USING TEFLON BASED RELEASE FABRIC WHEN CURING MAIN SPAR, BE SURE TO LIGHTLY SAND SURFACE AREA WHERE SHEAR WEB BONDWILL TAKE PLACE) 0.60"-1.00"
2.500"
(BASED ON 24 PLIES OF UNIAXIAL MAT'L)NOTE: PULL TABS (.007" THK) WILL EXTEND OUT FROM SPECIMENEDGE DURING CURE PROCESS, BE SURE TO USE SPECIALCARE NOT TO PUNCTURE VACUUM BAG (COVER SHARPEDGES WITH BREATHER FABRIC) . PULL TABS REMOVED AFTER CURE PROCESS.
1 of 2NOTES:
1. SPECIMEN CURED USING 14 IN. HG. VACUUM PRESSURE AND VACUUM LEFT ON OVER NIGHT.
2. POST CURE SPECIMEN AT 70 C FOR 10 HOURS.
3. FINAL FLAT BOTTOM HOLE DEPTH MAY CHANGE DEPENDING ON FINAL PART THICKNESS.
1.875"
2.750"
2.750"
2.750"
2.750"
2.750"
(41)
(42)
(43)
(44)
(45)
(46)
(52)(51)
(50)(49)(48)
(47)
(53)(54)
(55) (56)(57)
(58)
(64)
(63)
(62)
(61)
(60)
(59)
(65) (66) (67) (68)
(69)
(70)
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Flaw types to include: snowflaking, porosity, resin-starved regions, voids, interply delaminations, spar and shear web disbonds, ply waviness
75% MR
Depth into adhesive & shear web skin
50% MR
25% MR
NDI Feedback Specimens 1, 2 & 4 –Shear Web & Foam Core Specimens
NDI Feedback Specimens 1, 2 & 4 –Shear Web & Foam Core Specimens
Rotor Blade CT System iHMSiP Shearography Dantec Dynamics
Shearography Laser Technology IncSonic IR WSUTerahertz Teraview
P Terahertz Radiation (T-Ray) Iowa State UniversityTerrahertz Imaging GMA Industries
Thermography AANCP Thermography Thermal Wave ImagingP Through Transmission AANC
Ties to QinetiQ Triton SystemsP TSCOUT (Thick Section Comp. UT) & PAC UT Mistras Group
UT and IR Systems TecScanUT Spectroscopy QinetiQ
Various NDI IHI Southwest TechnologiesP Vibro Thermography ResodyneP MAUS Phased Array UT AANCP RotoArray - Phased Array UT GE Inspection Technologies
WINDIE – Advanced NDI Screening ActivityWINDIE – Advanced NDI Screening Activity
• Flaw detection peformance (type, sensitivity)• Duration of inspection• Fieldability (contact/noncontact)• Deployment issues• Inspection difficulties• Cost of new system• Accessories needed to make fieldable• Ease of data interpretation
Information gathered during round-robin inspections:
• Ultrasonic probes consists of 16 to 256 individual elements• Can produce A, B, and C-scans• Low frequency (0.5 to 1.5 MHz) for deep penetration • Multiple deployment options
Sandia LabsMethod: MAUS V PE Focus Probe
with Water Column
Sandia LabsMethod: Phased Array UT
25mm Water Box
Phased Array UT – Display and DeploymentPhased Array UT – Display and Deployment
Olympus 1.5Mhz, 42 element probe
Sonatest RapidScan 2
GE Phased Array UT RotoArray
ShearographyShearography
Sandwich core specimenThick laminate with bond lines
• Uses vacuum, heat, vibration to monitor the surface of a structure for changes in the surface strain field/displacement
• Wide area interferometric imaging technique that is capable of detecting micron-sized displacements
ThermographyThermography
• Thermography relies on the heat absorption characteristics of the structure and changing IR images/heat transfer curves to indicate the presence of defects
Terahertz RadiationTerahertz Radiation
C-scans gated around the returning time of flaw sets
PILLOW INSERTS
MICRO-BALLOONS
PULL TABS
2.00" DIA. 1.50" DIA. 1.00" DIA. .50" DIA.
Test specimen flaw profile
• 50 GHz – 4 THz frequency range with air-coupled, high penetration• Flaws detected through frequency attenuation, phase shift and time of
flight • Changes in THz signatures can indicate degradation of material as well• Pitch-catch mode allows for single-sided inspections
methods which address array of flaw types (data fusion)
Tom Rice, Dennis Roach, Stephen Neidigk, Randy Duvall and Josh Paquette
Sandia National Labs Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security
Purpose• Generate industry-wide performance curves to quantify:
how well current inspection techniques are able to reliably find flaws in wind turbine blades (industry baseline)
the degree of improvements possible through integrating more advanced NDI techniques and procedures.
Expected Results - evaluate performance attributes 1) accuracy & sensitivity (hits, misses, false calls, sizing) 2) versatility, portability, complexity, inspection time (human factors) 3) produce guideline documents to improve inspections 4) introduce advanced NDI where warranted
An Experiment to Assess Flaw Detection Performance in Wind Turbine Blades (POD)
An Experiment to Assess Flaw Detection Performance in Wind Turbine Blades (POD)
Wind Blade NDI Probability of Detection ExperimentWind Blade NDI Probability of Detection Experiment
- Blind experiment: type, location and size of flaws are not know by inspector- Statistically relevant flaw distribution – Probability of Detection (POD)- Used to analytically determine the performance of NDI techniques – hits,
misses, false-calls, flaw sizing, human factors, procedures
Experimental Design Parameters• Representative design and manufacturing• Various parts of blade such as spar cap,
bonded joints, leading and trailing edge• Statistically valid POD (number, size of flaws
and inspection area)• Random flaw location• Two days to perform experiment• Deployment
Fabrication Considerations• Realistic, random flaw locations• Portable sample set• Range of thickness• Material types (fiberglass, carbon and various
adhesives)• Who will manufacture
Spar Caps & Shear Web Box Spar & Shear Webs
Designed to be applicable to various blade construction
An Experiment to Assess Flaw Detection Performance in Aircraft Composite Structures
An Experiment to Assess Flaw Detection Performance in Aircraft Composite Structures