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  1. Home
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  3. Aerospace Metrology
  4. Airframes
  5. Cfrp Hole Delamination

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CFRP Hole Delamination

CFRP delamination from R&D to manufacturing and defect inspection

Carbon fibre reinforced polymer (CFRP) components are increasingly common in the Aerospace and Automotive industries due to their excellent mechanical properties, most notably their high strength to weight ratio.  CFRP components are manufactured by laying several uncured resin/fibre plies on top of each other.  Once lay-up is complete the material is cured, fusing the plies and giving the material its final properties. Prior to final assembly, it is often necessary to drill fastener holes in CFRP components which can result in a separation of the plies, known as delamination. This delamination can create weakness and result in premature part failure and is a major cause of costly part rejection in manufacture. This report, from the University of Sheffield Advanced Manufacturing Research Centre (AMRC) was undertaken to help industry develop economic methods of controlling drilling-induced delamination.

CFRP delamination from R&D to manufacturing and defect inspection
In-service delamination inspection

In-service delamination inspection

CFRP delamination is a serious problem for airplanes in service as it can significantly impact the structural integrity. It can be caused by several factors, the most common being:

Impact damage: This can be a result of a foreign object such as hail or ground service equipment, commonly referred to as Barely Visible Impact Damage (BVID)

Fluid Ingress and Icing: If water enters the structure through small cracks and around fasteners and freezes the expansion can cause layers to separate leading to delamination.

Fatigue and Stress: Load and unload cycles experienced during flight can cause defects to grow, leading to delamination.

Internal damage inspection can be by carried out via NDT techniques such as ultrasonic testing, tap testing or eddy current testing, while external damage can be visually inspected. However, this is often subjective and does not provide any metric data.

The 4DInspec is a handheld optical profiler designed to measure surface level defects on all surfaces, including CFRP. It will measure defects from 5µm to 9mm deep with a field of view up to 15mm x 15mm with a vertical resolution between 2.5 µm & 7 µm (model dependent) and automatically calculates key defects such as maximum height, volume, and area, Slopes and location, Defect density and aspect ratio. 

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Alicona µCMM

Delamination due to the drilling of composite material is a widespread problem within the aerospace industry. The high-quality output of the Bruker Alicona μCMM system, coupled with its ability to rapidly scan multiple holes, allows for the opportunity to develop a reliable automated method of hole delamination inspection.

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Alicona µCMM

The Optimax team with their extensive knowledge and expertise, have proven themselves to be the ideal partner for independent, candid advice. They are a company we can trust to support our metrology and visual inspection needs whether we are purchasing equipment or developing specific metrology instruments for our applications. Their experience and methodical attention to detail mean the outcomes we achieve support our testing requirements.

Dr Andrew Johnson, Assistant Director, RandA

Optimax are a trusted partner! We have been working in partnership with Optimax for several years, to supply us with inspection solutions, service, and onsite calibration to UKAS standards. Their knowledge and expertise is exceptional, they provide honest, independent advice. Optimax are quick to provide options and solutions for our inspection requirements. They work hard to deliver a solution that 100% fits the application rather than just supplying a product. Optimax work with us to ensure we achieve our inspection objectives – they are one of the first companies I turn to.

Bruce Daggett, Senior Aerospace Weston, Inspection Team Leader

For over 14 years Optimax has been providing us with inspection equipment, service and most importantly expertise. We need suppliers that can go the extra mile in looking specifically at our application and then providing a suitable and sometimes bespoke solution, and this is where Optimax have really made a difference

John Harris, Director, Nevo Developments

Optimax have an extensive product range that was very attractive to us. They took the time to understand my requirements and align a solution that fitted into my manufacturing processes. They were very knowledgeable and friendly, I found the virtual demonstration extremely helpful. The outcome of the project has been very successful and performs above expectations. I would definitely recommend Optimax.

Adam Kowalcyck, Quality Engineer, Federal Mogul Coventry

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