ASTM E2580-07

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation:E2580–07
Standard Practice for
Ultrasonic Testing of Flat Panel Composites and Sandwich
Core Materials Used in Aerospace Applications
This standard is issued under the fixed designation E2580; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope both sides of the specimen. This procedure is automated and
the examination results are recorded.
1.1 This practice establishes two procedures for ultrasonic
1.4 This practice does not specify accept-reject criteria.
testing (UT) of flat panel composites and flat sandwich core
1.5 This standard does not purport to address all of the
panels (parallel surfaces).Typical as-fabricated lay-ups include
safety concerns, if any, associated with its use. It is the
uniaxial, cross ply and angle ply laminates; as well as honey-
responsibility of the user of this standard to establish appro-
comb sandwich core materials. These procedures can be used
priate safety and health practices and determine the applica-
throughout the life cycle of the materials; product and process
bility of regulatory limitations prior to use.
design optimization, on line process control, after manufacture
inspection, and in service inspection. Contact methods such as
2. Referenced Documents
angle-beam techniques using shear waves, or surface-beam
2.1 ASTM Standards:
techniques using Lamb waves, are not discussed.
C274 Terminology of Structural Sandwich Constructions
1.2 Ultrasonic testing is a common sub surface method for
D3878 Terminology for Composite Materials
detection of laminar oriented discontinuities. Two techniques
D5687/D5687M Guide for Preparation of Flat Composite
can be considered based on panel surface accessibility; pulse
Panels with Processing Guidelines for Specimen Prepara-
echo for one sided and through transmission (bubblers/
tion
squirters) for two sided. As used in this practice, both require
E114 Practice for Ultrasonic Pulse-Echo Straight-Beam Ex-
the use of a pulsed straight-beam ultrasonic longitudinal wave
amination by the Contact Method
followed by observing indications of either the reflected
E543 Specification for Agencies Performing Nondestruc-
(pulse-echo) or received (through transmission) wave. The
tive Testing
general types of anomalies detected by both techniques include
E1309 Guide for Identification of Fiber-Reinforced
foreign materials, delamination, disbond/un-bond, fiber de-
Polymer-Matrix Composite Materials in Databases
bonding, inclusions, porosity, and voids.
E1316 Terminology for Nondestructive Examinations
1.3 This practice provides two ultrasonic test procedures.
E1434 Guide for Recording Mechanical Test Data of Fiber-
Each has its own merits and requirements for inspection and
Reinforced Composite Materials in Databases
shall be selected as agreed upon in a contractual document.
E1471 Guide for Identification of Fibers, Fillers, and Core
1.3.1 Test Procedure A, Pulse Echo (non-contacting and
Materials in Computerized Material Property Databases
contacting), is at a minimum a single transducer transmitting
2.2 SAE Standards:
and receiving a longitudinal wave in the range of 0.5 to 20
ARP 5605 Solid Composite Laminate NDI Reference Stan-
MHz (see Fig. 1). This procedure requires access to only one
dards, Issued 2001-09
side of the specimen. This procedure can be conducted by
ARP 5606 Composite Honeycomb NDI Reference Stan-
automated or manual means. Automated and manual test
dards, Issued 2001-09
results may be imaged or recorded.
2.3 AIA Standard:
1.3.2 Test Procedure B, Through Transmission, is a combi-
NAS-410 Nondestructive Testing Certification of Personnel
nation of two transducers. One transmits a longitudinal wave
and the other receives the longitudinal wave in the range of 0.5
MHz to 20 MHz (see Fig. 2).This procedure requires access to
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
This practice is under the jurisdiction of ASTM Committee E07 on Nonde- the ASTM website.
structive Testing and is the direct responsibility of Subcommittee E07.06 on Available from Society of Automotive Engineers (SAE), 400 Commonwealth
Ultrasonic Method. Dr., Warrendale, PA 15096-0001, http://www.sae.org.
Current edition approved July 1, 2007. Published July 2007. DOI: 10.1520/ Available fromAerospace IndustriesAssociation ofAmerica, Inc. (AIA), 1000
E2580-07. WilsonBlvd.,Suite1700,Arlington,VA22209-3928,http://www.aia-aerospace.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
E2580–07
FIG. 1 Test Procedure A, Pulse Echo Apparatus Set-up
FIG. 2 Test Procedure B, Through Transmission Apparatus Set-up
2.4 ASNT Standards: 3. Terminology
SNT-TC-1A Recommended Practice for Personnel Qualifi-
3.1 Definitions—Terminology in accordance with Termi-
cation and Certification in Nondestructive Testing
nologies C274, E1316, and D3878 shall be used where
ANSI/ASNT CP-189 Standard for Qualification and Certi-
applicable.
fication or Nondestructive Testing Personnel
3.2 Definitions of Terms Specific to This Standard:
3.2.1 flat panel composite, n—any fiber reinforced compos-
5 ite lay-up consisting of laminate (plies) with one or more
AvailablefromAmericanSocietyforNondestructiveTesting(ASNT),P.O.Box
28518, 1711 Arlingate Ln., Columbus, OH 43228-0518, http://www.asnt.org. orientations with respect to some reference direction that are
E2580–07
consolidated by press or autoclave to yield a two- The scanning and indexing apparatus should have sufficient
dimensionally flat article of finite thickness. structural rigidity to provide support for the manipulator and
3.2.2 sandwichcorematerial,n—astructuralpanelmadeup should allow smooth, accurate positioning of the search unit.
of two relatively thin outer skins of composite laminate or The scanning apparatus should be sufficiently rigid to keep
othermaterial,suchasmetalorwood,separatedbyandbonded search unit backlash to within tolerances as specified in the
to a relatively thick lightweight inner core such as honeycomb, contractual agreement.
open and close cell foam, wave formed material, bonded 6.1.7 Tank or Gantry System—The tank or gantry system
composite tubes, or naturally occurring material such as balsa should permit accurate positioning of the search unit, reference
wood. standards, and part or material to be examined.
6.1.8 Squirter—The squirter equipment shall be capable of
4. Summary of Practice supplying a laminar flow of coupling fluid from the transducer
to the part being tested at all angles used.
4.1 This practice describes two procedures for detecting
6.1.9 Scan-Record—The recording shall not exhibit back-
anomaliesinflatpanelcompositeandflatsandwichcorepanels
lash or hysteresis that would hinder detection or evaluation of
using ultrasonic longitudinal waves coupled by either contact
discontinuities.
(Procedure A) or bubbler/squirter (Procedure B). Equipment,
6.1.10 Composite Reference Blocks—For the applicable
reference blocks, examination and evaluation procedures, and
testing system the responses from reference block and part
documentation are described in detail.
shall be similar to the extent that standardization of the testing
system can be accomplished and demonstrated to provide a
5. Significance and Use
known and acceptable detection level in the part. Reference
5.1 This practice is intended primarily for the testing of flat
blocks contain either structural anomalies or foreign inclu-
panel composites and sandwich core panels to an acceptance
sions. Structural anomalies are those that are known to be
criteria most typically specified in a purchase order or other
possibleduringthelifecycleofthematerial.Debondingduring
contractual document.
manufacturing or delamination during in-service may be rep-
5.2 Basis of Application—There are areas in this practice
resented by the block. Foreign inclusions most commonly
that require agreement between the cognizant engineering
encountered during manufacturing are used in the reference
organization and the supplier, or specific direction from the
blocks.
cognizant engineering organization.
6.1.11 Transfer Cutouts—When non-contact through-
transmission is used transfer cutouts may be used in lieu of
6. Equipment and Materials
reference blocks when agreed upon contractually. The size of
6.1 Equipment
the transfer cutouts shall be agreed contractually. The transfer
6.1.1 Operation—Test equipment shall be capable of pro-
cutouts must provide sufficient attenuation to simulate voids or
viding uniform, repeatable, and controlled operation.
unbonds in the part. Transfer cutouts shall be attached to the
6.1.2 Electronic Equipment—The electronic equipment
part and be placed to cover changes in part configuration and
should be capable of producing and processing electronic
alignment.
signals at frequencies in the range of search unit frequencies
6.2 Materials:
being used.
6.2.1 Flat Panel Specimens—Processing guidelines that
6.1.3 Search Unit(s)—The search unit(s) selected should be
facilitate fabrication of flat panel composite specimens made
compatible with the electronic equipment being used and with
fromunidirectionaltapeorusingorthogonalweavepatternsare
the material to be inspected. The search unit should match the
found in Guide D5687/D5687M. For specimen preparation
intended squirter(s) or contact. Only straight-beam (longitudi-
using other processing techniques, for example, pultrusion,
nal)searchunits,withflatorfocusedacousticlenses,shouldbe
filament winding and resin transfer molding, processing guide-
used.
lines are not available and shall be agreed upon by the using
6.1.4 Alarm—The alarm or threshold level should be ad-
parties.
justable to allow triggering at any commonly required level of
6.2.2 Sandwich Core Specimens—Processing guidelines for
indication amplitude. Alarms are not required on systems that
fabricationofsandwichconstructionspecimensarediverseand
record amplitude recordings.
shall be agreed upon by the using parties.
6.1.5 Alarm Gate Synchronization—In the pulse echo mode
6.2.3 Transfer Cutouts—Transfer cutouts shall be made of
ensure that the alarm gate tracks the inspection area. The gate
two layers of lead foil tape cut to size.
shouldlockonthefirstinterfacepulsefromthetestpiecerather
6.2.4 Couplants—Immersion and contact couplants shall
than on the initial pulse from the system. In the through
provide intimate coupling between search unit and part; shall
transmission mode the alarm gate should be wide enough to
be compatible with the part; and shall be easily removed from
cover any negative or positive movement (left to right) in the
the part using an applicable cleaning process.
horizontal plane.
7. General Requirements
6.1.6 Manipulating Equipment should be provided to ad-
equately support the search tube(s) and allow angular adjust- 7.1 In-process testing of flat panel composite or honeycomb
ment in two mutually perpendicular planes. The search unit structure shall be conducted using automated equipment ca-
manipulator shall be capable of providing the adjustments pable of electronically recording the test output or manual
necessary to properly position the search unit during testing. contact during indication evaluation. There shall be a direct
E2580–07
correlation of the electronic recording and the tested specimen. 7.5 Material Condition—Perform ultrasonic testing of parts
Transducer frequency shall be determined by the material’s or materials that possess a clean and smooth surface.
7.6 Coverage—In all examinations, perform scanning to
apparent attenuation and the required acceptance criteria. Scan
locate discontinuities that are oriented parallel with the entry
increment shall be set to provide three ultrasonic signal
surface. The index increment shall be such that the target
violations from the standard at the specified threshold level.
simulated anomaly registers three times at a contractually
7.2 If required by contract, evaluation of the agency per-
agreed upon threshold.
forming testing shall be in accordance with Practice E543.
7.7 Ultrasonic Frequency—For a particular test select the
7.3 In-service testing shall be conducted using manual
frequency based on the material being inspected and of the
contact techniques, these tests are for the determination of
anticipated type of discontinuities.
suspected areas of damage. Testing shall be conducted using a
7.8 Evaluation—Evaluate each discontinuity to determine
referencestandard.Thisreferencestandardshallbeofthesame
its type, size, location and conformance to the applicable
configuration as the test specimen or as agreed upon contrac-
accept/reject criteria. Specific discontinuity evaluation proce-
tually. This reference standard shall be acoustically similar and
dures shall be agreed upon contractually.
contain simulated or actual discontinuities.
7.9 Technique Record—For each part inspected, a technique
7.4 In-process testing of flat panel composites shall be for
record shall be completed for each discontinuity detection scan
the detection of foreign materials, delaminations, voids and
and indication evaluation set-up used. The technique record
porosity. In-process testing of honeycomb structures shall be
shall identify the part, the area or zone, or bond-line of the part
for the detection of non-bonds between the face sheets and
being inspected, the inspector, the inspection procedure, and
core. In-service testing of flat panel composites shall be for the the equipment used. The record shall include cross-sectional
detection of damage such as delaminations. In-service testing
sketches as necessary to show part coverage. The technique
of honeycomb structure shall be for unbond between the face record shall note instrument control settings such that the test
sheet and core. can be repeated.
TEST PROCEDURES
8. Procedure A 8.2.2.1 Clean surface of part and apply the contact couplant
that provides the most consistent signal. Select a probe that
8.1 Test procedure A (Pulse-Echo) is a single transducer
provides at least a 3:1 signal to noise response from reference
transmitting and receiving a longitudinal wave in the range of
standard and provides proper indication sizing capabilities.
0.5 MHz to 20 MHz (see Fig. 1). This procedure can be
8.3 Standardize the System
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