Comparison of Different NDT Techniques for Evaluation of the Quality of PCBs Produced Using Traditional vs. Additive Manufacturing Technologies.

Multilayer printed circuit boards (PCBs) can be produced not only in the traditional way but also additively. Both traditional and additive manufacturing can lead to invisible defects in the internal structure of the electronic component, eventually leading to the spontaneous failure of the device. No matter what kind of technology is used for the production of PCBs, when they are used in important structures, quality control is important to ensure the reliability of the component. The nondestructive testing (NDT) of the structure of manufactured electronic components can help ensure the quality of devices. Investigations of possible changes in the structure of the product can help identify the causes of defects. Different types of manufacturing technologies can lead to diverse types of possible defects. Therefore, employing several nondestructive inspection techniques could be preferable for the inspection of electronic components. In this article, we present a comparison of various NDT techniques for the evaluation of the quality of PCBs produced using traditional and additive manufacturing technologies. The methodology for investigating the internal structure of PCBs is based on several of the most reliable and widely used technologies, namely, acoustic microscopy, active thermography, and radiography. All of the technologies investigated have their advantages and disadvantages, so if high-reliability products are to be produced, it would be advantageous to carry out tests using multiple technologies in order to detect the various types of defects and determine their parameters.

Ultrasonic Features for Evaluation of Adhesive Joints: A Comparative Study of Interface Defects.

Ultrasonic non-destructive evaluation in pulse-echo mode is used for the inspection of single-lap aluminum adhesive joints, which contain interface defects in bonding area. The aim of the research is to increase the probability of defect detection in addition to ensuring that the defect sizes are accurately estimated. To achieve this, this study explores additional ultrasonic features (not only amplitude) that could provide more accurate information about the quality of the structure and the presence of interface defects. In this work, two types of interface defects, namely inclusions and delaminations, were studied based on the extracted ultrasonic features in order to evaluate the expected feasibility of defect detection and the evaluation of its performance. In addition, an analysis of multiple interface reflections, which have been proved to improve detection in our previous works, was applied along with the extraction of various ultrasonic features, since it can increase the probability of defect detection. The ultrasonic features with the best performance for each defect type were identified and a comparative analysis was carried out, showing that it is more challenging to size inclusion-type defects compared to delaminations. The best performance is observed for the features such as peak-to-peak amplitude, ratio coefficients, absolute energy, absolute time of flight, mean value of the amplitude, standard deviation value, and variation coefficient for both types of defects. The maximum relative error of the defect size compared to the real one for these features is 16.9% for inclusions and 3.6% for delaminations, with minimum errors of 11.4% and 2.2%, respectively. In addition, it was determined that analysis of the data from repetitive reflections from the sample interface, namely, the aluminum-adhesive second and third reflections, that these contribute to an increase in the probability of defect detection.

Exciting and Detecting Higher-Order Guided Lamb Wave Modes in High-Density Polyethylene Structures Using Ultrasonic Methods.

High-density polyethylene (HDPE) pipes are becoming increasingly popular, being used in various fields, such as construction, marine, petroleum, water transfer, process water, methane gas collection, oil and gas gathering, gas distribution systems, mining, acid and wet gas lines, offshore oil and gas and in nuclear power plants. Higher-order guided Lamb wave (UGW) modes can be used to detect various defects in complex structures. We will apply this methodology to one of the types of plastic-the structure of high-density polyethylene (HDPE). However, the excitation of UGW modes faces numerous challenges, especially when there is a need to identify which mode is excited. It is essential to note that, in the higher frequency range, multiple different higher-order modes can usually be excited. This can make it difficult to determine which modes have actually been excited. The objective of this research was to successfully excite and receive various higher-order UGW modes in high-density polyethylene structures using both ultrasonic single-element transducers and a phased array. Theoretical calculations were performed using a variety of methods: semi-analytical finite element (SAFE) method, 2D spatial-temporal spectrum analysis and finite element modeling (FEM). The results obtained from both measurements and simulations clearly demonstrate the possibility of efficiently exciting and receiving different Lamb wave modes possessing different phase velocities.

Numerical Analysis of Guided Waves to Improve Damage Detection and Localization in Multilayered CFRP Panel.

Multilayered carbon fiber-reinforced polymers (CFRP) are increasingly used in aircraft components because of their superior mechanical properties. However, composite materials are vulnerable to impact loads, resulting in delamination-type damage which, if unnoticed, could lead to catastrophic structural failure. The objective of this research was to investigate possibilities to improve damage detection and the localization using signal processing methods. Numerical modeling using the semi-analytical finite element (SAFE) method was performed to obtain guided wave dispersion curves and to perform modal analysis. From the modal analysis, A0 mode for inspection of the composite with delamination type defects was selected. From the numerical simulation, A0 mode interaction with delamination along the longitudinal direction was analyzed and the location of the defect was estimated by measuring the time of flight (ToF) of the signal using Hilbert transform (HT) and continuous wavelet transform (CWT). The CWT has shown better results in estimating the delamination location compared with HT. The depth of delamination was characterized in the frequency domain by comparing the amplitude of the A0 mode. Inverse fast Fourier transform (IFFT) is recommended to reconstruct the reflected and transmitted modes for better damage detection and to reduce the complexity of signal interpretation.

Novel Processing Algorithm to Improve Detectability of Disbonds in Adhesive Dissimilar Material Joints.

Adhesively bonded dissimilar materials have attracted high interest in the aerospace and automotive industries due to their ability to provide superior structural characteristics and reduce the weight for energy savings. This work focuses on the improvement of disbond-type defect detectability using the immersion pulse-echo ultrasonic technique and an advanced post-processing algorithm. Despite the extensive work done for investigation, it is still challenging to locate such defects in dissimilar material joints due to the large differences in the properties of metals and composites as well as the multi-layered structure of the component. The objective of this work is to improve the detectability of defects in adhesively bonded aluminum and carbon fiber-reinforced plastic (CFRP) by the development of an advanced post-processing algorithm. It was determined that an analysis of multiple reflections has a high potential to improve detectability according to results received by inspection simulations and the evaluation of boundary characteristics. The impact of a highly influential parameter such as the sample curvature can be eliminated by the alignment of arrival time of signals reflected from the sample. The processing algorithm for the improvement of disbond detectability was developed based on time alignment followed by selection of the time intervals with a significant amplitude change of the signals reflected from defective and defect-free areas and shows significant improvement of disbond detectability.

Comparison of Ultrasonic Non-Contact Air-Coupled Techniques for Characterization of Impact-Type Defects in Pultruded GFRP Composites.

This article compares different air-coupled ultrasonic testing methods to characterize impact-type defects in a pultruded quasi-isotropic glass fiber-reinforced plastic (GFRP) composite plate. Using the air-coupled transducers, comparisons among three methods were performed, namely, bulk-wave through transmission, single-side access using guided waves, and ultrasonic-guided wave tomography. The air coupled through transmission technique can determine the size and shape of impact-type defects with a higher resolution, but with the consequence of time consumption and, more importantly, the necessity of access to both sides of the sample. The guided wave technique on the other hand, allows a single-side inspection and is relatively fast. It can be used to determine the size of the defect using ultrasonic B-scan, but the exact shape of the defect will be compromised. Thus, in this article, to determine the shape of the defect, application of the parallel beam tomographic reconstruction technique using guided Lamb waves is demonstrated. Furthermore, a numerical finite element simulation was performed to study the effects of guided wave propagation in the composite sample and interaction with the internal defect. Lastly, the results from the experiments of different techniques were compared according to possibilities of defect sizing and determination of its shape.

Evaluation of Bonding Quality with Advanced Nondestructive Testing (NDT) and Data Fusion.

This work aims to compare quantitatively different nondestructive testing (NDT) techniques and data fusion features for the evaluation of adhesive bonding quality. Adhesively bonded composite-epoxy single-lap joints have been investigated with advanced ultrasonic nondestructive testing and induction thermography. Bonded structures with artificial debonding defects in three different case studies have been investigated: debonding with release film inclusion, debonding with brass film-large, debonding with brass film-small. After completing preprocessing of the data for data fusion, the feature matrices, depending on the interface reflection peak-to-peak amplitude and the principal component analysis, have been extracted from ultrasonic and thermography inspection results, respectively. The obtained feature matrices have been used as the source in basic (average, difference, weighted average, Hadamard product) and statistical (Dempster-Shafer rule of combination) data fusion algorithms. The defect detection performances of advanced nondestructive testing techniques, in addition to data fusion algorithms have been evaluated quantitatively by receiver operating characteristics. In conclusion, it is shown that data fusion can increase the detectability of artificial debonding in single-lap joints.

Micro-Computed Tomography (Micro-CT) Evaluation of Effects of Different Rotary Glide Path Techniques on Canal Transportation and Centering in Curved Root Canals.

BACKGROUND The aim of this study was to evaluate the ability of different rotary glide path techniques to maintain canal anatomy by comparing canal transportation and centring abilities in curved root canals using X-ray micro-computed tomography (micro-CT). MATERIAL AND METHODS We selected 36 root canals and randomly assigned them to 3 groups. The first group was instrumented using Pathfile (PF) 1 and PF2, the second group using PF2, and the third group using a Proglider (PG) instrument. Selected tooth samples were scanned using a micro-CT system with 8-µm resolution. Centring ability and transportation were compared at 5 levels: 0.5 mm (A0) and 1 mm (A1) from apical foramen, at the point of maximum root curvature (C0), at 1 mm below it (C-), and 1 mm above it (C+). Area, ratio of areas (RA), perimeter, centroid shift, mean diameter, and ratio of diameter ratios (RDR) were assessed. RESULTS In all groups, there were no significant differences between different levels in all parameters (p>0.05). In group 1, the centroid shift was greatest at A0 and C-, and the least impact was at C0. In group 2, the biggest impacts were at C- and A0, and the smallest at C+. In group 3, the greatest impacts were at A0 and A1, and the smallest at C0. CONCLUSIONS All 3 instrument groups performed very similarly, without significant differences in canal-shaping parameters. Overall, using just PF2 instead of PF 1 and 2 created very similar shaping results, which could reduce the number of instruments needed and the cost of treatment.

Ultrasonic non-destructive testing of complex titanium/carbon fibre composite joints.

Ultrasonic inspection is widely used for non-destructive evaluation of composite adhesive joints. However, there are serious challenges in applying ultrasonic testing on metal to composite hybrid joints, because they are multi-layered, made out of dissimilar materials and relatively thin. The ultrasonic signals reflected by different layers are overlapped, scattered and attenuated. The aim of this research was to develop an ultrasonic inspection technique suitable for defect detection in hybrid metal to composite joints where the metal part has pin arrays, which entangle with the composite part. The immersion pulse echo technique was used to collect data. In order to overcome the problems related to the rough surface and non-parallel layers a novel signal post-processing algorithm for reconstruction of the joint area was developed and validated experimentally. It is shown that using the proposed technique the positions of different defects can be determined.