1. Introduction
The use of carbon fiber reinforced polymers (CFRP) is becoming increasingly common due to the possibility of producing robust yet lightweight components, as required in many automobile or aviation applications, as well as in marine and civil engineering. The wide design space of the final material characteristics of the product, which can be highly customized, is another noticeable feature of CFRP [
1,
2].
The growing usage of CFRP has raised the demand for solutions related to inspecting such materials. In particular, the positioning and orientation of fibers during manufacturing are aspects of great interest, because they can significantly affect the strength and stiffness of composite components [
3,
4], but require specific inspection methods for the identification of irregularities.
Non-destructive evaluation (NDE), which is carried out at predetermined intervals, and continuous structural health monitoring (SHM), or its advanced version as prognostics and health monitoring (PHM), which also permits forecasting and avoiding any sudden critical failure, as part of the manufacturing process and during their in-service lifetime, are necessary for the effective use of composites in a wide range of applications [
5,
6].
The production process of composites is complex and involves several factors. As a result, there is a significant probability of various errors occurring, which heightens the importance of safety issues throughout the product’s life. This makes NDE even more important during the production process.
It should be also considered that the part inspection is a time-consuming process, so the accurate, fast, and possibly automatable, fiber orientation assessment is a desirable target for production quality control.
Filament winding is a particular production process for composite components, which involves wrapping continuous filaments coated with resin around a rotating mandrel in specific patterns, to create an axisymmetric composite structure. Once the desired thickness is achieved, the structure is cured and the mandrel is removed, leaving a hollow composite part [
7,
8].
In this kind of process, the winding angle represents a particularly critical parameter, as it determines the mechanical characteristics of the component, and any irregularities in the movement of the winding head are reflected in fiber orientation defects. These defects, in turn, can cause secondary flaws, such as the presence of voids or alterations in thickness [
9]. These different types of defects appear particularly critical if the components are subject to high internal pressures, as happens in the case of tanks or pipes for pressurized fluids, therefore the problem of identifying defects for product quality control, even during manufacturing, or for process optimization purposes, appears particularly important for safety reasons.
For these reasons, in this paper, some solutions for analyzing the fiber orientation in a carbon fiber cylinder, obtained through a filament winding process, will be explored, highlighting, in particular, the metrological aspects involved in this type of investigation.
There are presently a lot of non-destructive techniques for detecting damage on composite structures like thermography, acoustic, ultrasonic, eddy current techniques, computed tomography imaging, and X-rays [
5,
10]. Computed tomography (CT) is one especially advanced non-destructive technique that offers geometrically precise subsurface imaging of a component, useful for visualizing and evaluating the fiber characteristics on CFRP components [
11,
12,
13]. One drawback of this technique is that the complete component scan is frequently unachievable due to the physical size of typical aerospace components [
11]. Furthermore, even in the most modern versions, CT scanners continue to be expensive and cumbersome.
In general, all the cited technologies allow for the study of the completed part or after failure, but they can’t provide guidance or support during the assembling process [
14].
Instead, vison-based methods are useful instruments for the online inspection of pieces [
15,
16]. The drawback of these techniques for CFRP inspection is that they are challenging to use in the case of non-optimal illumination conditions and, as happens in many cases, glossy surfaces [
1]. Many approaches based on edge detection and conventional image processing are proposed, but these need high-resolution and quality pictures, which are not always easily achievable, taking into account operational and surface characteristics [
8,
17].
It has recently been shown that carbon fibers alter the direction of the reflected light electrical field, so that in each point of the surface of a CFRP piece the angle of polarization of reflected light matches the fiber orientation: this phenomenon allows to use a particular branch of the computer vision, the polarization technique, to analyze the characteristics of the CFRP weave [
1,
8,
18].
Polarization vision has become a well-established field overall, and it has long been employed in photography to prevent gloss and mirror effects, and to improve visibility [
19], and, in more recent applications, it has been also used in high-dynamic-range (HDR) imaging [
20], in the orientation and navigation field [
21], for characterizing birefringent fluids [
22], for studying acoustical phenomena [
23]. Its application to the particular subject of composite component inspection is still relatively new [
1,
24].
Modern sensors exist, which collect polarized light in four planes (at 0°, 45°, 90°, 135°) using microscopic polarizing filters on each pixel. Based on the intensities obtained for each pixel, related to the polarized light in the four directions, it is possible to compute, through the Stokes parameter analysis [
10], the angle of linear polarization (AoLP), which aligns with the fiber angles on the surface under investigation. If the incident light is assumed to be unpolarized, then any induced polarization in the observed reflected light is solely caused by the reflected light’s electric field aligning with the fibers. This property is still present when resin is applied on the carbon fiber component.
This method, compared to non-vision methods, on average offers the following advantages [
1]:
On the other hand, it must be considered that:
the inspection is limited at the uppermost visible layer (but in the specific problem of fiber orientation analysis, this may not be a limitation)
it is unsuitable for glass fibers
Compared to other computer vision methods, polarization is [
1]:
On the other hand, polarization cameras offer, on average, a lower resolution and are slightly more expensive than traditional ones.
Given the interest in online inspection methods of fiber orientation for composite material components, the authors intend to delve into the metrological aspects related to the use of the polarized camera for the measurement of the winding angle.
The approach followed in this article for the fibers angle measurement is similar to that described by [
1], which involves analyzing the AoLP distributions, and evaluates the distance between peaks, to determine the angle between tows.
In [
1], however, the variability analysis is based on the evaluation of the standard deviation of the identified Gaussian distributions, which is also affected by dust or loose fibers on the surface. This assessment is believed to be an overestimation of the uncertainty, considering that the angle measurements are obtained by averaging a large number of values, equal to the number of pixels corresponding to that specific angle. In addition, the absence of a reference for the fiber angles makes it difficult to evaluate errors, which are assessed relative to nominal values. Furthermore, the paper identifies the aspects of greatest influence on the measurement: lighting mode, camera settings, and surface curvature. However, a structured approach to evaluating these factors’ effects and interactions is missing.
In this paper, a design of experiment (DOE) will be carried out to estimate the combined effect of exposure time, lens aperture, and distance of the lighting system, with the aim of identifying the optimal system settings and estimating their impact on the variability of measurement. Furthermore, an uncertainty assessment will be carried out combining the main uncertainty contributions.
This metrological analysis is deemed innovative by the authors with reference to the inspection by polarization, compared to the state of the art in this field.
In addition, in the present work a study of the trend of the winding angle along the surface of the cylinder under analysis will be carried out, in order to obtain useful information for the optimization of the production process.
2. Materials and Methods
2.1. Vision System
A FLIR Blackfly S BFS-PGE-51S5P camera is used to capture the component surface. This monochrome polarization camera is based on the Sony IMX 250 CMOS sensor, and has a native resolution of 5.0 Mpixels (2448 (H) x 2048 (W) pixels). The pixel size is 3.45 µm and incorporates a four-direction polarizer formed on the photodiode of the chip. With this special construction, it is possible to capture simultaneously the polarization information in four different directions. Microscopic filters are present on each pixel with polarization directions as described in
Figure 1: from top-left to bottom right, they are 90°, 45°, 135° and 0°.
To trade-off between the working distance and minimizing the perspective distortion, 25 mm low distortion lens are used in this paper.
Two soft boxes equipped with 80 W white bulbs are employed as light sources. With this setup is possible to illuminate the component under analysis with a diffused and non-polarized light. This kind of illumination system is chosen for this application due the dimensions of the component under analysis. To reduce the ambient light influence, the component is placed inside a white box and away from ceiling lights.
Images are acquired in RAW file format to preserve all the information from the camera sensor using Spinnaked SpinView acquisition software.
Figure 2.a shows a scheme of the acquisition setup where the softboxes are placed at Sd1 and Sd2 distance, respectively, from the component surface, while
Figure 2b depicts the developed vision system with camera, illuminators and the component under analysis.
2.2. Component Under Analysis and Test Plan
This work focuses on the study of a non-planar component, in particular, a composite cylinder that represents a part of a pressure vessel. This part is made by means of a filament winding process using carbon fiber and epoxy resin towpregs. All the materials used in the manufacturing process are commercially available. For the carbon fiber, Toray T700S-12K-50C was used, whereas the resin system was a Huntsman Araldite Solution, composed of the Araldite LY 3508 as epoxy resin, the Aradur 1571 hardener and the Accelerator 1573 as accelerator [
9]. The obtained tows are wound in layers on a stainless-steel rotating mandrel. The winding pattern consists of an initial hoop layer where the tows are wound with a winding angle close to 90° to promote adhesion of the subsequent helicoidal layers. The nominal winding angle for these last layers is 60°.
The cylinder under analysis has an internal diameter of 200 mm and a total length of 300 mm. To study the component’s surface, it is inspected along two longitudinal directions and three circumferential lines. The longitudinal directions, L1 and L2, are about 70° spaced from each other. For the circumferential lines, one, C2, is positioned on the central section of the component while the others, C1 and C3, are placed 65 mm apart on the left and on the right from the previous one. The component and its subdivision are reported in
Figure 3.
The quantity of interest to be measured is the winding angle, which can be obtained starting from the angle between the tows (2β), as the difference between 90° and the angle β, as explained in
Figure 4.
Following the considered division of the surface, along the longitudinal directions 4 areas are examined, while on the circumferential lines 22 areas are analysed. The test plan provides three repeated acquisitions for each considered area of the cylinder, repositioning each time the component.
The setting condition under which to carry out the tests are established in advance using a design of experiment (DOE) which minimizes the variability of the results.
Optimizing and characterizing a vision system for the application of interest is not trivial since several parameters influence the result. For this reason, a DOE approach is employed to systematically study the effects and the relationship between different factors. In this case, three parameters are investigated: the distance between the soft boxes and the component under analysis, exposure time, and lens aperture. The lighting system distance defines how much light illuminates the component surface. The exposure time is the amount of time the camera sensor records the light. Using low times, the pixels are very dark, resulting in images with poor signal to noise ratio (SNR). On the other hand, longer exposure could lead to overexposure and saturations on the image. Lens aperture directly affects the amount of light that enters the camera sensor, thus influencing the overall brightness of the photo.
A 2
3 experiment is designed, where two levels are considered for each factor, as reported in
Table 1. With this experiment design, eight different factors combinations are possible resulting in as many settings. Each of them is independently replicated for three times considering the same area on the cylinder surface. Furthermore, the experiment runs are performed in random order.
2.3. Data Analysis
The acquired images are processed using MATLAB
®, release 2023b. To exploit the extra information a polarization camera provides, the first pre-processing step is to “demoisaic” the captured images. From the RAW file format following the scheme provided in
Figure 1, the pixel intensity for each direction is extracted from the original acquisition. As a result of this step, there are four images, one for each polarization direction. The resulting images have a resolution of 1224 (H) x 1024 (W) pixels, one fourth of the original size. The reduction in the final image resolution is a negative aspect of this kind of polarization camera.
The state of the polarized light can be obtained from the pixel intensity Iθ for each direction θ (0°, 45°, 90°, 135°), using the Stokes parameter, as classically indicated by the scientific literature in the field [
1,
14,
25]:
From these parameters, it is possible to calculate the Degree of Linear Polarization (DoLP) and the Angle of Linear Polarization (AoLP). DoLP represents the ratio of the intensity of the polarized to the intensity of the unpolarized part of the light, ranging from 0 (for unpolarized light) to 1 (for totally polarized light). AoLP defines the angle of maximum polarization. From the Stokes parameters, DoLP and AoLP are calculated using the following equations:
In this case, the AoLP function is calculated using the inverse tangent function that returns values in the range [-90; 90] (angle measured from the vertical direction, clockwise).
In the case study, to reduce the effect of the complex shape of the component, the images obtained are split in three parts where only the central one is considered as the Region of Interest (RoI) for further analysis.
Then, the distribution of the AoLP in the central RoI is studied. It should be distributed according to a bimodal distribution, because there are two prevailing directions of the fibers constituting the winding of the composite material. The bimodality characteristic can be studied using the Bimodality Coefficient (BC) [
26]:
where S is the skewness, K is the kurtosis and n the sample size. If the value of this index is more than the critical value of 5/9 ≃ 0.56 it suggests bimodality of the distribution [
26].
Other metrics can be considered to further evaluate the characteristics of the bimodal distribution, for example, the Bimodality Amplitude (BA) and the Bimodality Ratio (BR) [
27]. BA is defined as the ratio of the smaller peak amplitude to the antimode amplitude of the fitted probability density function (PDF). It is always less than or equal to 1 and larger values indicate more distinct PDF peaks. BR is the ratio of the right and the left amplitude peaks of the PDF, indicating which of the two dominates.
Then, in the case of the cylinder, for each image acquired, the AoLP data are plotted on a histogram, and are fitted using the sum of two Gaussians distributions. Finally, the mean angle between tows (2β) is evaluated by identifying the angles corresponding to the peaks of the two fitted distributions and calculating their difference (the distance between them).
It is important to emphasize that the angles corresponding to the peak of each Gaussian are average values of the angles obtained in all the pixels of the image corresponding to that direction. Therefore, the winding angle that is obtained is an average value over the area analyzed: this average value represents the measurand in this paper.
The working distance of the camera is set to 190 mm. This provides a good trade-off between the extension of the acquired surface, and the influence of the curved shape of the component of interest: this aspect will be deepened in the next Section. The experiment results are compared considering the variability of the fibers angle, that is chosen as desired output (response) of the DOE. Once the optimal settings for the vision system are identified, the cylinder surface is analyzed.
2.4. Uncertainty Assessment
The uncertainty assessment is carried out considering the following components:
Repeatability of the measurements on the same area: it is evaluated by conducting three repeated measurements for each examined area, on three different images. In each acquisition the component is repositioned. Then, the maximum difference D between results is calculated and the uncertainty contribution is determined, considering a rectangular distribution, as:
Variability of the measurement on the surface analyzed: standard deviation calculated on the bases of the measurements made along the circumferential lines of the cylinder, since in these directions, during the winding process, the pulling forces of the deposition head can be considered constant. For this reason, theoretically, all the tows should be wound at the same angle on the rotating mandrel. This contribution comprises the variability of the measurand along the circumferential lines.
Contribution of the setting parameters: the influence of the parameters is evaluated as the standard deviation of the mean values of the measured tow angles obtained in the different acquisition setups considered in the DOE. The largest difference D’ in winding angles is identified, and the contribution to the uncertainty is assessed, considering a rectangular distribution, as:
The shape of the object under analysis should be considered as another source of uncertainty since the reflected light polarization is also influenced by the curvature of the surface. For this reason, the camera axis is positioned in radial direction respect to the cylinder, and the measurement is performed in a central band of the image (width ~ 20 mm), which has been identified taking into account the highest DoLP values, as will be shown in the Results Section. In this way, the curvature effect is expected to be negligible respect to the other contributions, also considering the limited extension of the inspected area compared to the diameter of the component (200 mm), so each area examined can be considered nearly flat.