Applying optical coherence tomography to inline quality monitoring of unidirectional glass-fiber-reinforced thermoplastic tapes

IF 3.6 4区 材料科学 Q2 MATERIALS SCIENCE, COMPOSITES Journal of Thermoplastic Composite Materials Pub Date : 2024-08-21 DOI:10.1177/08927057241259756
Michael Wenninger, Karin Kloiber, Christian Marschik, Gernot Hochleitner, Gerald Berger-Weber, Georg Steinbichler
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Abstract

Originally developed for biomedical applications and diagnosis, optical coherence tomography (OCT) has recently been demonstrated to be a powerful non-destructive and non-invasive measurement method for detecting defects in glass-fiber reinforced polymer composites. While previous studies have focused mainly on the use of OCT in the analysis of thermoset composites, we were able to show in offline experiments that OCT can be used to quickly detect typical defects (e.g., dry fiber regions, gaps and fiber breakage) in thermoplastic unidirectional (UD) tapes at high resolution. To investigate the applicability of OCT to inline monitoring, we advanced our previously published approach in two major steps: First, we incorporated the OCT system into an industrial-scale UD-tape production line, and derived optimal settings for inline detection of dry region defects from a comprehensive design of experiments (DoE) to find an optimal balance between accuracy and data size for a stationary tape sample by varying A-scan sampling rate, A-scan averaging and OCT transverse travel velocity. Second, using these optimal settings, we went on to investigate moving tapes over a range of industrially relevant take-off speeds. Microscopy was used for validation in both cases. We developed a fast and robust statistical analysis of B-scans that visualizes the quality of full cross-sections in an interpretable manner for potential use in a real-time setting. Within an industrially relevant production speed range of up to 15 m/min, we are thus now able to investigate 120 mm wide (and potentially wider) UD tapes inline at a transverse resolution of 22 µm, producing only 21 MB of data per measurement.
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将光学相干断层扫描技术应用于单向玻璃纤维增强热塑性塑料胶带的在线质量监测
光学相干断层扫描(OCT)最初是为生物医学应用和诊断而开发的,最近已被证明是一种强大的非破坏性和非侵入性测量方法,可用于检测玻璃纤维增强聚合物复合材料中的缺陷。虽然以前的研究主要集中在使用 OCT 分析热固性复合材料,但我们能够在离线实验中显示,OCT 可以用于以高分辨率快速检测热塑性单向 (UD) 胶带中的典型缺陷(如干纤维区域、间隙和纤维断裂)。为了研究 OCT 对在线监测的适用性,我们通过两个主要步骤推进了之前发布的方法:首先,我们将 OCT 系统集成到工业规模的 UD 胶带生产线中,并通过综合实验设计 (DoE) 得出了在线检测干区缺陷的最佳设置,通过改变 A 扫描采样率、A 扫描平均值和 OCT 横向移动速度,找到静态胶带样本的精度和数据量之间的最佳平衡。其次,利用这些最佳设置,我们继续研究了在一系列工业相关起飞速度下的移动磁带。在这两种情况下都使用了显微镜进行验证。我们开发了一种快速、稳健的 B 扫描统计分析方法,以可解释的方式直观显示全横截面的质量,可用于实时环境。因此,在最高 15 米/分钟的工业相关生产速度范围内,我们现在能够以 22 微米的横向分辨率在线检测 120 毫米宽(甚至可能更宽)的 UD 带,每次测量仅产生 21 MB 的数据。
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来源期刊
Journal of Thermoplastic Composite Materials
Journal of Thermoplastic Composite Materials 工程技术-材料科学:复合
CiteScore
8.00
自引率
18.20%
发文量
104
审稿时长
5.9 months
期刊介绍: The Journal of Thermoplastic Composite Materials is a fully peer-reviewed international journal that publishes original research and review articles on polymers, nanocomposites, and particulate-, discontinuous-, and continuous-fiber-reinforced materials in the areas of processing, materials science, mechanics, durability, design, non destructive evaluation and manufacturing science. This journal is a member of the Committee on Publication Ethics (COPE).
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