Bond Interface Evaluation of Solid Woven Carbon Fiber Composite onto Aluminum Alloys

Solid woven carbon fiber reinforced plastic (CFRP) consists of two or more components. The constituents retain their individual material properties in the composite matrix at the macroscopic level. Generally, one of the materials acts as a reinforcing agent and the other constituent serves as a polymeric binder for the carbon weave. The binder also creates covalent bonds between the composite and metal surface. All composites and metal-to-composite interfaces contain voids and micro-cracks. These manufacturing anomalies result in higher ultrasonic noise signals in the A scans. The B and C-scans produce a textured appearance. The interaction of sound dispersion and absorption within the composite makes the bondline interface between reinforced plastic and metal more difficult to evaluate. This paper explores nondestructive inspection techniques to evaluate the bondline and documents the elastic wave scattering through the metal-to-composite interface. A summary of the detection and analysis techniques developed to identify: lack of bonding and porosity levels within a solid laminate and bondline are presented.

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