Total NDT Solutions for Aerospace

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1 One Source for Asset Protection Solutions SOLUTIONS BULLETIN Total NDT Solutions for Aerospace INNOVAtive SOLutionS MISTRAS Products & Systems Division is a team of researchers, engineers, skilled technicians and manufacturing personnel dedicated to the development of solutions to your challenging testing needs. For over 30 years, we have been providing both standard and custom non-destructive solutions to assure structural integrity and design and to detect flaws in a wide range of aerospace applications. MISTRAS Group s global network employs seasoned NDT professionals specializing in non-destructive testing products, systems, on-line monitoring, field inspection, and research and applications development. The Group s headquarters in Princeton Junction, NJ are tasked with application research, engineering product design, ultrasonic and mechanical engineering and manufacturing. ActiveLY involved in... Composite repair and patch integrity Integrity of aging metal Impact detection and classification for composite and hybrid assemblies Crack detection and classification Ultrasonics testing of aerospace components and structures Serving the Aerospace Industry At MISTRAS, we have served the aerospace industry with many firsts, starting with the supply of 20 systems to Boeing in the early 1980 s. We have since led the way with pioneering non-destructive testing (NDT) work on several aerospace structures for Boeing, Airbus, GD, Lockheed, British Aerospace, SAAB and many others. Today we design and manufacture a broad line of ultrasonic systems for the aerospace industry, challenged by today s use of advanced composites and by the need to maintain aging designs. (UT) Ultrasonic Aerospace Solutions We offer a full range of ultrasonic inspection systems designed to service your diverse aerospace testing needs. From fully automated industrial C-Scan systems for flat plate, forging, bar & billet and specialty composites inspection to portable mini scanners for use on in-service aerospace structures, MISTRAS has grown from designing and manufacturing premier Ultrasonic System Cards (Data Acquisition/ Pulser Receiver/Digitizer) to now supplying precision, industrial high speed inspection scanning systems. Our comprehensive components product line includes full Windows XP A/B/C scan software with RF storage, clustering analysis and 3D image displays. We offer a full range of PCI system cards including our ADIPR-1210 integrated 100 MHz, 12-bit digitizer/30 MHz pulser receiver, with capabilities in accuracy and speed that are not easily matched by our competitors. In addition, we offer an interface option of our scanners to Phased Array instrumentation, providing C-Scan imaging capability. At MISTRAS we are not just another systems integrator, we design and manufacture all the major components of our systems in-house and thus have total control over specifications, costing and performance, and offer turnkey system solutions.

2 Broad Range of Industrial Ultrasonic Systems and Scanners IndUSTRIal UT SySTems Our Industrial Ultrasonic Immersion Systems product line includes a variety of product sizes, all designed to provide a rugged solution for the inspection of metallic or nonmetallic components of all geometries in harsh industrial environments. Our Industrial 6 axis scanner is a high speed, full contour following stainless-steel tank assembly. Applications include, billet, plate, random and other specialty composite parts inspection. It s rugged, precise and fast! In additional our industrial hardened systems can be custom designed for any size and the number of automated axes including stainless steel turntables. The systems software is capable of automated image analysis, defect sizing. The systems are a proven aerospace metals supplier work horse. Heavy-Duty Missile Scanner Our heavy duty missile scanner was developed for the military. Utilizing squirter technology, this portable (breaks down at dry dock) turnkey system detects propellant delaminating in the VLA burn stage. The precision bar stock rotator was specifically designed to quickly inspect aerospace tubing (metals and composite) components. An environmentally protected data acquisition system (DAS), the bar rotator has rugged industrial construction, servo drive motion control, long life and zero maintenance linear drives. It has been designed for 20 years productive service. New Linear Motor Technology For precise image quality, a linear motor driven scanner offers faster and more meticulous scanning detail than stepper or servo motors. A finer degree of mechanical control ensures high frequency, high accuracy scans with no backlash. And, fewer moving parts means less maintenance and wear and a much quieter scan. Our imaging systems now offer linear motor technology in a variety of scanner sizes, for custom manufacturing to your specific requirements. Key Gantry Features Ability to operate in either machine axes or component axes. System Manager/Programmer/Operator access levels with only the appropriate menus and options available at each level. Comprehensive manual and automatic learn procedures. Ability to mathematically add further internal surface lines providing different scan start positions, or for leading on to a more detailed automatic surface learn. Full 3D image rotation enabling the part surface to be viewed from any direction. Mathematical surface extension to allow the over scanning of edge regions. Full control of all possible scan parameters and machine variables. Fast network communications with the data acquisition system for scan control synchronization during scan start and scan error recovery. Provision of data acquisition trigger pulses synchronized with the complex contoured surface being tracked during scanning motion even during acceleration and deceleration phases to ensure the correct spacing of ultrasonic acquisition points throughout the whole part surface. Ability to stop a scan then return the next day and continue from where you left off with both systems being automatically setup as before through the motion control scan plan and the acquisition workspace. Area re-scan capability initiated by selecting a region from an acquisition image leading to only that region being re-scanned with the ultrasonic data being over-written facilitating the removal of air bubble or other spurious effects. Return to defect capability enabling the machine to be positioned back directly over a defect for further analysis. Ultra High Resolution Systems For an ultra-high resolution requirement, our Mini-Sam ultrasonic microscope delivers with a staggering MHz bandwidth. This high resolution system is designed to resolve the needs of most any avionic or thin ceramic, bonded diamond coated cutting tooling and IC chip applications. Bar/Billet Rotator UT System This product line consists of a variety of heavy duty, mill ready systems designed to provide a solution for the inspection of metallic or non-metallic tubular geometries. With a high speed, all stainless steel Bar/Billet Rotator, the system is able to hold up to 6,000 pound components while providing 100 percent sub-surface Ultrasonic inspection of critical aerospace metallic components. UT Tank Systems Our UT Scanning Systems are used for nondestructive testing of advanced materials. This system scan an entire volume of different composite metals along with detecting and quantifying irregularities such as delaminations, cracks and voids. The system gives you the option to produce and test composites at your own facility without outsourcing. The MISTRAS UT Tank System is part of our product line of immersion inspection and gantry systems. The systems can be customized for Multi-Axes configuration and uses the UltraWin C-Scan based software. High Precision Multi-Axes Complex Contour Following UT Gantries MISTRAS has teamed with proven top of the line gantry manufactures and leaders in the industry to provide mechanical gantries and motion control packages, to combine our UT digital data acquisition package presenting the ultimate in precision UT Gantry Systems. Their innovation in machine design and the use of advanced material technology provides our customers with increase performance and reliability than was previously possible. Their extensive experience has culminated in the development of the most advanced UT Scanning Systems, We still continue to offer our cost effective brand of smaller custom designed gantry systems for applications that are scaled down in size and performance requirements.

3 Data Acquisition & Analysis Software Solutions UT Immersion System Retrofits Modernize the performance and operation of your older Ultrasonic immersion systems and substantially increase scanning speeds with state-of-the-art data collection, analysis and reporting software, coupled with highperformance system components. Multi-Channel Digital Data Acquisition Full C-Scan using UTwin 1-10 axis active or passive upgrades X/Y 5-Phase Stepper; Servo Motion Control AD1210-IPR, GE approved Pulser with A/D Rebuild or replace Motion Components Refurbish or enlarge Stainless tanks On-site installation - Finished in 2-4 days UTwin : OUR full Featured UltraSonic C-Scan Software UTwin is our 3rd generation 32 bit, true Windows data acquisition, ultrasonic c-scan imaging and analysis software. Built from our industry standard UltraWin, UTwin is user-friendly with intuitive pull-down menus, independent C-Scan pages and feature icons. It is packed with features such as multiple real time A, B and C-Scan displays, coupled with powerful post-processing modes like zoom, pan, size/measure, RF replay, cluster characterization and export to MS Excel. More advanced features include multiple gates with individual velocities, raster or polar plotting, full contour following, slave gates, back wall followers, phase detection gates, feature ratio gates and many more. UTwin supports up to 8 ultrasonic channels from multiple GE approved AD-1210-IPR PCI cards, NDTA 4/8 channel multiplexers and other external pulser receivers. Display multiple gate outputs on individual C-Scans, mix zoomed plots, customized 3D and 4D views. It s all built in! Mix any combination of C-Scan, B-Scan, numeric plots and even 3D views. Just click, add and size. If you re running out of room, simply add another page to easily build your own custom display. UTwin interfaces to most other tanks and scanners and all of ours. Simply configure the motion and UT setups with easy to use pulldown menus. UTwin Acquisition Features 4 Flaw Gates Phase/Slave Gate, Back Wall Follower, MAC Multiple C-Scan pages Multi Layer Gage Up to 16 Channels Supports 32 Channel Mux User-defined C-Scan pages (A,B,C or combo) Supports sever JSR Pulsers & Acquisition Logic 1-3 GHz A/D boards UTwin Contour Following Features Supports complex contour following Supports auto gimbal and water path 16 axes control Array Integration Interfaces to most commercially available phased array systems UTwin motion control software provides scanning controls for phased array systems Embedded Drivers for... Pulsers, Receivers, and Digitizer Modules AD-IPR-1210, MISTRAS 100 MHz PR/AD Card PR-1210,MISTRAS 100 MHz PR Card PR-60, or JSR-300, JSR P/R MUX1615, MISTRAS 8-Channel Multiplexer Panametrics-5910, Panametrics H.F. P/R WaveGen 1410, Arbitrary Waveform Gen. Acquisition Logic 1-3 GHz A/D boards AD-81G, MISTRAS 1 GHz Others can be integrated upon request Flexible Hardware Configurations Conventional multi axes X,Y and Z Scanners Turntables Bar Rotators Multi-Channel Gantry 6 16 axes of motion control Lab Scanners Industrial Hardened Scanners Custom Design Systems includes software and hardware System upgrades and retrofits Phased Array/Linear Array system integration Pulse Echo or Through Transmission Modes Passive Encoder feedback C-Scan imaging UTwin Replay software Cluster analysis supports section or full screen area image analysis Cluster analysis can evaluate total cluster or above a threshold. 3D Replay, rotation and zoom Process screen support for Boeing and common signal-to-noise calculation More palette options and embedded palettes Supports flaw classifications (auto clustering) Supports direct export to XLS files Image Displays A-Scan/RF, full and pos./neg. half wave B-Scan/Real-time or post analysis (save RF waveforms) C-Scan/Amplitude, Time-of-Flight Any combination of displays on one screen DAC /TCG Curve displayed FFT Spectrum Analysis display Multi Channel: Multiple A-Scans on one screen, Multiple C-Scan on one screen 3-D Image, Amplitude and Time-of-Flight, Contour following C-Scan image Image Annotation Image Container Graph: Post analysis image stitching or arrange a variety of images for comparison or reports Transducer Characterization Program (TCP) to Profile UT Transducers per ASTM E-1065 Phase Inversion: Display C-Scan images as a result of a RF phase shift Statistical Graphs: Graphing test results as a bar graph image Statistical Table: Post analysis display of testing results Cluster Analysis: C-Scan image w/threshold detected defects marked for easy analysis Auto Flaw Analysis Software: Auto analysis qualifying detected indication and displaying only qualified defects. Provides Pass/Fail Report. Analysis provided seconds after the scan is completed.

4 Providing Total NDT Solutions for Aerospace UT Boards Integrated Pulser/Receiver Boards, Designed & Manufactured In-house The AD-IPR-1210 board is a 12-bit, analog to digital converter with an integrated highperformance 300 Volt (400 optional) pulser/ receiver module. Utilizing a 10-layer SMT (Surface Mount Technology) printed circuit board, this high speed, extremely low noise PCI-bus card is designed for wide bandwidths and fits into one standard PCI slot on a GE DFO approved PC. With a tunable (50 nanoseconds to over 1 microsecond) programmable pulse width, the pulser/receiver can be optimized to work with 20 MHz to < 500 khz transducers. Transducer Characterization ProgrAM (tcp) Per AStm E-1065 TCP is an automated digital ultrasonic beam profiling system which uses feedback motion control and image processing techniques to profile your ultrasonic immersion transducers. The system consists of a three-dimensional mechanical scanner, a host computer, a PC plug-in Pulser/Receiver, a PC plug-in digitizer board and a PC plug-in motor controller board. The powerful software package can automatically control and dynamically adjust the movement of an immersion transducer over a target to profiling the transducers sound beam profile characteristics. It also combines the functions of a digital oscilloscope and FFT spectrum analysis to analyze the transducers frequency, bandwidth, damping and signal sensitivity. This system follows the guidelines set out in the ASTM recommended practices for transducer characterization, E THERMAL inspection Licensed from NASA and further refined by MISTRAS, our Line-Scanning Thermography (LST) is a dynamic thermography technique that has been successfully used for detecting regional alterations in the thermal properties of the inspected material, making it possible to find defects like delaminations, impact damage and inclusions hidden inside composite structural components in production or on the flight line. The LST can also be applied to various materials such as composite structures, concrete surfaces and other material that will react to thermal excitation evaluation. LST has the ability to detect delaminations in concrete surfaces and sub-surfaces along with complex composites and sandwich honeycomb structures Motion Control SMC-8 & Aerotech Boards A high performance, servo and stepper motor and encoder interface board available as either a 4 or 8 channel version. The board provides a complete (up to 8 axis) motion control solution. The stepper motor controller board is a highperformance board with extreme accuracy in positioning and high-speed position readout capability for each axis. Features of the board are the ability to select an acceleration and deceleration profile independently for each axis. Several modes are available: trapezoidal mode, S-Curve or custom design acceleration/deceleration rate. The maximum number of pulses can reach 500Kpps, which gives the board the ability to drive micro-stepping motor systems directly. Arbitrary Waveform Generator Boards ARB-1410 is a PCI PCI-bus based, highly precise (14-bit), high speed (100 M Sample/ sec), arbitrary waveform generator card. Using WaveGen1410 Software, it is capable of providing an extensive variety of simple or complex acoustic emission waveforms of all shapes and amplitudes up to +/- 150 Volts. ARB-1410 uses digital synthesis to generate an analog output waveform. Waveform sample points are clocked from the RAM buffers via FPGA (Gate Array) to a high speed 14 bit digitalto-analog converter stage (the Waveform DAC) at rates up to 100M Samples per second (based on the setting of the programmable Timebase generator). PortABLe ultrasonic System The Pocket UT battery-operated, handheld, stand-alone, full C-Scan data acquisition system. With its portability and ease of use, coupled with its full A, B & C-Scan capability, the Pocket UT (along with available companion scanners or other compatible devices) is ideal for on-site inspection applications. It quickly assesses the presence, depth, shape and orientation of cracks, flaws, corrosion/erosion, delaminations, and internal anomalies in a variety of structures, materials and surfaces. It can operate as a conventional thickness meter (for spot readings), a basic flaw detector with RF display and alarm gates, or in either active B-Scan or full C-Scan data acquisition, display and analysis. It can be integrated with virtually any available single or dual-axis scanner (with standard interfaces), manual or automated, (with conventional or dry-coupled UT transducers). The system has an easy-to-use keypad for fast entry of common commands for detailed data entry and a LCD screen data presentation user interface. Heat Lamp Camera

5 Largest Gantry installed at HITCHO Carbon Composites

6 Customized NDT Solutions for Aerospace Portable UT Scanners The Auto X-Y Scanner, designed with internal stepper motors, provides automated movement of the scanner for position feedback. An LSI type sensor mount is provided so that an LSI type Bubbler/Gimbal & Swivel Transducer holder and assembly (optional) can be attached. A small, portable, AC or battery operated Scanner Control box provides the necessary power and motor drivers to operate the motorized X-Y stage. A scanner interface cable which connects directly to the Pocket UT motion control connector is also provided, for ease in setup and operation of the Pocket UT with the scanner. Non-Contact (Air-Scan) UT Materials that need to be ultrasonically inspected and cannot be contaminated with any couplant, requires a non-contact inspection solution. Air coupled ultrasonic systems apply to materials that are compliant to low frequency ultrasonic sound waves, thus Non-Contact Ultrasonic Testing. Non-Contact Ultrasonic Testing frequency ranges from as low as 50 khz to as high as 1MHz. The lower frequencies are used for thicker material and more attenuative materials to sound transmission like honeycomb structures or complex composite materials. The higher frequencies are used for thinner materials that are less attenuative to sound transmission like multi layer composite material. The inspection technique used is through transmission where the transmitter transducer faces the receiver transducer with the inspection material placed in between. Phased Array automated Scanning Both UTwin and NDTA digital motion controllers can be configured to work with leading vendors Phased Array systems. Using Phased Array can result in greatly reduced scanning times by using the PA probe in a linear array mode thus reducing the index spacing by the PA probes width. Although PA scanning can add considerable costs, for some applications the increase in speed warrants the expense. We have supplied systems integrated with both Omniscans and Focus LT systems for a seamless, turnkey automated PA system delivery to the user. WORLDWIDE HEADQUARTERS: 195 Clarksville Rd Princeton Jct, NJ USA T: F: sales@mistrasgroup.com Visit our website for an office near you Local Presence, Global Reach!