Electromagnetic test systems and test methods

Drapery testing of carbon fiber structures with gray image from volume information of the material under examination.

High-frequency eddy current

 

Fraunhofer IKTS applies the high-frequency eddy current technology and imaging impedance spectroscopy in a frequency range from 100 kHz to 100 MHz. It is used to test various materials, from metals to non-conductive materials, like ceramics (SiC) and plastics. Thus, structures of electrically weak conductive materials classes, such as carbon fibers and their composites, can be made visible, as well. Regarding carbon fiber structures, properties, like fiber orientation, impacts, breaks, delaminations or ondulations can be detected and characterized, and fiber bundle distributions evaluated. By texture analysis, angles between layers, lane widths, distributions or anomalies are quantified at curved surfaces.

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Freeform scanner for testing transformed materials.

Measurement automation

 

Based on parameter studies e.g. of novel materials, Fraunhofer IKTS determines suitable parameters. They are used to design, produce and deliver all components necessary for an automation of testing, like deposited preamplifiers, multiplexers and circuit boards of the detectors (arrays). The test systems are integrated by customized assembly of periphery components.

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OCD device of Fraunhofer IKTS as 3D CAD layout.

Design and realization of mechanical components for prototypes

 

The development of sensors, devices and methods includes the frequent setup of laboratory demonstrators, prototypes and pilot plants, but also special test bodies. With the 3D CAD system, first drafts are developed, which are realized by the in-house workshops in the form of small- and medium-sized tools and prototypes.

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EddyCus® electronics for high-frequency eddy current testing.

Electronics and software development

 

Fraunhofer IKTS develops customer-specific solutions in the form of certified laboratory and industrial software for controlling measurement data acquisition as well as evaluation and administration of data. Analogous to the Fraunhofer IKTS ultrasound suite PCUS®pro LAB, nearly all established interface specifications can be integrated. On request, database interface, user administration und automated report creation can be added, too.

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CFRP texture analysis at arbitrarily formed structures.

CFRP materials competence

 

High competence in materials is a prerequisite for manufacturing first-class products. Fraunhofer IKTS is equipped with an excellent know-how in methods and CFRP materials along the whole value chain. With the EddyCus® high-frequency eddy current method for carbon textile testing, Fraunhofer IKTS is technology leader and first contact for industry and research with regard to quality assurance in the CFRP fabrication process.

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3D image of a battery.

Industrial computed tomography

 

By industrial computed tomography (ICT), objects of a wide variety concerning size and homogeneity (from pure metals to fiber composites) are investigated and three-dimensionally visualized. Fraunhofer IKTS generates three-dimensional images from the cross-sections, which are subsequently used in defect analysis.

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Bonding wires (8 µm) and bumps with embedded pores.

High-resolution laminography

 

By High Resolution Computed Laminography (HRCL), it is possible to analyze materials of low density, complex devices made of different materials and objects of high density. This tomographic method is used to non-destructively obtain a spatial representation of internal and external structures with a resolution of up to 2 μm³. By a special adjustment of x-ray tube and detector, the planar sample can be positioned near the x-ray source at full freedom of rotation. Die generated 3D data sets facilitate geometric measurements of distances, angles, arcs and surfaces as well as the determination of partial volumes in regions of varying density.

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Analysis of the condition of ferromagnetic materials with Barkhausen noise.

Micromagnetic diagnosis methods (Barkhausen noise and leakage flux measurements)

 

Mechanical load, temperature and corrosive environmental influences cause materials fatigue in nearly all large-scale industrial plants over time. If exogenous overload is not perceived in time, the operators of ferromagnetic large-scale plants are threatened by failure of components or even the whole plant. Micromagnetic diagnosis methods, like Barkhausen noise and leakage flux measurements, are exceedingly suitable for condition analysis of ferromagnetic materials. Fraunhofer IKTS uses these measurement parameters to determine materials fatigue, hardness, hardening depth as well as stress within all ferromagnetic materials classes. Based on such in-situ inspections, the residual life time can be predicted by means of the determined measurement parameters.

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