Automated NDT inspection based on high precision 3-D Thermo-Tomography model combined with engineering and manufacturing data

Besides final inspection of components, NDT can be used during manufacturing in terms of monitoring and even controlling process quality. In addition, components are tested during their life cycle using various NDT methods. Evaluation and defect localization in 3-D is an enormous improvement towards automation. For this purpose, multiple different NDT images should be combined in three-dimensional space to improve the efficiency of the inspector in order to determine defect size and position accurately. The paper recommends an NDT inspection on large and complex components to ensure a closed-loop manufacturing process from CAD designs to real components. The main goal is to manage knowledge from the automated manufacturing processes and to reuse them with NDT inspection data in an analysis environment, i.e CATIA^TM. The DLR Augsburg is researching on robot-based automated thermoplastic CFRP manufacturing processes with inline-NDT inspection. Active thermography is the NDT method of choice because it is capable of visualizing defects on dry carbon fiber preforms as well as on consolidated parts. The proposed system aims firstly to collect the manufacturing process data automatically, and secondly generates a 3-D thermo-tomography model out of several 2-D thermal images. A smart manufacturing pick-and-place system with digital workflow and an automated spot welding process was used to preform 104 thermoplastic cut pieces. For the thermography investigation and traceability of defect detection depth on consolidated components, artificial defect anomalies were placed in predefined positions and depths. The results of the automated 3-D thermo-tomography model combined with engineering and manufacturing data were then confirmed with computed tomography results.