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Non-Destructive 3D Integrity Testing of Composite Material

Electron Resonance Analysis Technology (ERAT). Non-Destructive 3D Integrity Testing of Composite Material Utilizing a Unique Corona Beam Technology. 7 Britain Drive New Britain, PA 18901 Phone: 215-230-4260 www.coronabeam.com. Gregory J. Gormley, President ConverTec Corporation.

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Non-Destructive 3D Integrity Testing of Composite Material

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  1. Electron Resonance Analysis Technology (ERAT) Non-Destructive 3D Integrity Testing of Composite Material Utilizing a Unique Corona Beam Technology 7 Britain Drive New Britain, PA 18901 Phone: 215-230-4260 www.coronabeam.com Gregory J. Gormley, President ConverTec Corporation

  2. Practical Non-Destructive Testing Solutions • Accurate • Reliable • Repeatable • Penetrate • Identify Internal Flaws • Location • Characterization • Savings • Material • Time • Labor

  3. 1953 to 2006 1953 Chevrolet Corvette, the first composite-bodied car 2006 Cadillac XLR, a composites showcase (Picture courtesy of Automotive Composite Alliances)

  4. Composite Structures Graphite fibers in a composite resin matrix. (Picture Courtesy of USC Center for Composite Materials) The most often used reinforcement is chopped glass fibers. (Picture Courtesy of Automotive Composite Alliance)

  5. Methods of Non-Destructive Testing • X-Ray Testing • Costly • Exposure • Limited Area • Limited Material • Time Consuming • Not Practical for 100% • CAT Scan Testing (Computerized Axial Tomagraphy) • Costly • Exposure • Limited Area • Limited Material • Time Consuming • Not Practical for 100%

  6. Methods of Non-Destructive Testing (Cont.) • Ultrasonic Testing • Ultra High Frequency • Highly Directional Sound Waves • Measures Thickness • Measures Substantial Internal Flaws • Analyzes Reflected Sound Wave Patterns • Eddy Current Testing • Electromagnetic Induction Principle • Measures Near Surface Cracks • Measures Thickness • Measures Metals and Composites

  7. Methods of Non-Destructive Testing (Cont.) • Phased Array Testing • Specialized Ultrasonic Testing • Sophisticated Multi-Element Transducer Array • Requires Powerful Software • Similar to Medical Ultrasound Images • Good Off-Line Testing

  8. Methods of Non-Destructive Testing (Cont.) • Corona Beam Testing (ERAT: Electron Resonance Analysis Technology) • Drawn Through Material • Frequency Imposed Electron Beam • Open Atmosphere • Safe Non-Harmful to Material or Operator • Accuracy to 0.5 Nanometer • Measures Molecular Structure • Measures Permeability and Porosity • Identifies Fissures • Tortuous Path Holes • Non-Catalyzed Material • 100% Testing Capability

  9. Laser Beam vs. Corona Beam Technology • ConverTec • Problem • Discovery • Technology • Funding • Awards • Publications • Patents

  10. Schematic of One Corona Beam Gun • Frequency Charge Beam • Beam is Drawn Through Test Material • Signal Frequency Changes are Digitized and Processed • 100% Real-Time Testing • Non-Destructive • Non-Contact

  11. Griebel-Gormley Aperture Effect • Array of Corona Beam Guns • Grounded Mandrel • Test Material • Holes, Pores, Loose Molecular Structure • Aperture Effect

  12. Noise: “Signature” of Good Material • Spectrogram In Decibel Coloration Over Time • FFT Spectral Analysis • Electrons Always Flowing

  13. Anomaly: Disruption of “Signatures” • Greater Flow of Electrons • Frequency Distortion of Harmonics • Decibel Level Rated on a Coloration Scale

  14. SEM Photos of Material Anomalies • 4 Micron Laser Drilled Hole • 40 Micron Fiberglass Debris • 2 Micron Formulation Porosity Defect • 40 Micron Formation Defect

  15. ViruShield Test System • Polyurethane Condom • 31 Corona Beam Guns • Testing 100% in One Revolution • Testing Time One Second • Testing to One Micron

  16. Contact Information Chant Engineering Co., Inc. www.chantengineering.com www.coronabeam.com www.hullindustries.com 7 Britain Drive New Britain, PA 18901 (215)230-4260 Fax: (215)230-4261

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