Providing Total Aerospace NDT Solutions with. . .Innovative Products. . .Technology Leadership. . . Decades of Experience. . .


Nov 18, 2013 (3 years and 8 months ago)


Providing Total Aerospace NDT Solutions
with. . .Innovative Products. . .Technology
Leadership. . . Decades of Experience. . .

Providing Total Aerospace NDT Solutions
with. . .Innovative Products. . .Technology
Leadership. . . Decades of Experience. . .

Your On-line Asset Integrity Management Group
G r o u p I n c.
A Wo r l d o f N D T S o l u t i o n s
Providing Total NDT Solutions for Aerospace
Innovative products, technology leadership and decades of experience. . .
For nearly thirty years, Physical
Acoustics Corporation (PAC)
has been providing Acoustic
Emission (AE) solutions to as-
sure structural integrity and
design and to detect flaws in
a wide range of Aerospace ap-
With the addition of NDT Auto-
mation and Vibra-Metrics, the
Group has extended its product
offering to include not only Tra-
ditional Nondestructive Testing
(NDT) technologies, but also
Advanced NDT methods as well.
This helps aerospace industry
companies solve their problems
and save money.
Our global network employs
seasoned NDT professionals,
specializing in NDT products,
on-line monitoring, field inspection, and research and applica-
tions development. The Group’s headquarters in Princeton,
NJ are tasked with R&D, product design, engineering and
Aerospace NDT
Structural integrity and quality control in the Aerospace in-
dustry is challenged by today’s use of advanced composites
and by the need to maintain aging designs.
MHG Products are actively involved in:
• Composite repair/patch integrity
• Integrity of aging metal
• Impact detection and classification for composite/hybrid
• Crack detection and classification
• UT Testing of Aerospace components/structures
These inspections are performed utilizing nondestructive
testing (NDT) technologies including Acoustic Emission (AE),
Immersion, Automated and Hand-held Ultrasonics (UT) and
Acousto-Ultrasonics (AU).
What is Acoustic Emission?
Materials and structures emit energy in the form of stress
waves (acoustic emission) as a result of sudden microstructural
change or movement. This is usually due to a defect related
phenomena, such as cracking or plastic deformation. The AE
propagates from the source throughout the structure. Elec-
tronic “listening” to these AE signals results in locating flaws
(defects) as they occur, across
the entire monitored area.
This provides “global” early
warning of pending problems or
eventual failure or information
on the structural health of the
All types of structures, includ-
ing aircraft, undergo continuous
loading and stressing. These
stresses eventually cause defect
growth (e.g. cracking) in weaker
or fatigued areas of the struc-
ture. AE is unique from all other
NDT methods in that it detects
the defect growth, in real time,
as it is occurring. On-line moni-
toring of an aerospace asset
assures its repair or replace-
ment long before a catastrophic
failure occurs, preventing loss
of life, environmental damage and costly repairs.
Complete Acoustic Emission Product Line
The instrumentation required to detect discrete acoustic
emission is sophisticated. The exact way in which signals are
gated, filtered and interpreted adds complexity, due to the
presence of background noise during the measurement.
PAC manufactures the world’s only complete AE product line,
starting with sensors and systems that utilize proprietary soft-
ware to perform extensive signal analysis after the hardware
amplification and processing. The combined results provide
a complete characterization of the suspect AE (signal) and
reliably detect the source phenomenon.
Standard AE Multichannel Systems
PAC’s all digital parallel processing AE systems, used in con-
junction with in-flight compatible configurations or during
fatigue testing (etc.) can accurately detect and localize struc-
tural integrity issues (cracks or delaminations) in aluminum
and composite aircraft/space craft structures.
Serving the Aerospace Industry
Since its inception in 1978, PAC has been serving the Aero-
space industry with many firsts. Starting with the supply of
20 systems to Boeing in the early 1980’s, we have led the way
with pioneering NDT work on several Aerospace structures
for Boeing, Airbus, GD, Lockheed, British Aerospace, SAAB
and more. Today, we design and manufacture a broad line
of AE equipment for laboratory and on-line flying monitoring
Physical Acoustics Corporation, NDT Automation, Vibra-Metrics
To accommodate the various Aerospace testing applications, PAC is
proud to be the only company in the world that provides a complete
multichannel product line, from a single channel hand-held unit and
two channel PCI Bus cards to sixty four channels in a single chassis
and two hundred forty channels in a multiple chassis system, all
LAN or wireless controlled.
AE Aerospace Applications
Testing composites with one of PAC’s sophisticated digital
Acoustic Emission systems, along with specially designed
sensors, reveals different types of failure mechanisms, such
as matrix debonding & cracking and fiber breakage. The test
results provide essential information that can be utilized
to improve upon composite designs and construction. Also,
knowing the potential failure mechanisms is crucial in the
design of on-line health monitoring systems.
Rocket Structural Health Management
with On-line Monitoring
In-flight acoustic emission (AE) has been successfully demon-
strated on-board the DC-XA Delta rocket as part of a structural
health management system. The AE system utilized was a
commercially available unit that was modified for autonomous
control and redesignated AEFIS, “acoustic emission flight
instrumentation system.” Its primary goal was to monitor
a section of the new composite liquid hydrogen tank during
takeoff, in-flight, landing and post landing maneuvers. This
system provided the necessary data and feedback information
to the on-board vehicle computers about the condition of the
structure, fuel tanks and fuel systems.
Solid Rocket Booster Motor (SRM) Monitoring
The United States Air Force and PAC have worked together
to perform AE research for the detection of high-energy
impacts on graphite epoxy motor cases (GEMs). A prototype
AE system to “remotely” monitor graphite-epoxy solid
rocket motor cases (GEM’s) was designed to detect and assess
damage caused by high energy impacts. Data handling and
wireless transmission capabilities were incorporated into
the system.
There are two key aspects to the system. One is a source
location algorithm and the other a method to differentiate
between high and low
energy impacts. The ba-
sis of the source location
algorithm is the under-
standing of the acoustic
behavior of graphite-ep-
oxy. Through a series of tests performed on an inert GEM,
attenuation and anisotropy studies were conducted. Using
the wave velocities obtained from the data, a preliminary
algorithm was designed. Also, by looking at the energy con-
tent of the rectified
waveforms for vari-
ous impact energies a
method to classify the
magnitude of the im-
pact was determined.
Helicopter Gearbox
and Drive Coupling
PAC has successfully
demonstrated the de-
tection of cracks in
helicopters by apply-
ing Neural Network
strategy of signal iden-
tification in real time.
Acoustic Emission systems and sensors are used to detect
drive train and power transfer train problems before cata-
strophic failure occurs. Acoustic emission-helicopter health
and usage monitoring system (AE-HUMS) is a device that was
developed for detecting damage in helicopter drivetrains
during operation.
A Phase II SBIR entitled “Acoustic Emission Monitor for Drive
System Coupling Crack Detection” was awarded to PAC for
the design and development of a semi-real time monitoring
system for early detection of cracks in diaphragm-type cou-
plings in aircraft engine drive systems. DC crack tests were
performed on V-22 (Osprey) test stand.
NASA X-37 Flaperon Tests
To provide monitoring support during load testing of advanced
flight hardware, a PAC (8) channel AE system is in use at NASA
Solid Rocket Booster Motor (SRM) Monitor-
ing Station.
AE Characterization of Advanced Composites
Members of MISTRAS Group Inc.
Location of AEFIS and AE sensors on a
DC-XA demonstrator rocket.
PAC’s AEFIS, multichannel
acoustic emission flight in-
strumentation system.
Before failure.During and after failure.
Dryden. AE plays an important role in crack and defect detec-
tion within the sensor suite of a fully instrumented service
load testing structure. Surfaces, structural members, attach-
ment points, and mechanical interfaces of advanced carbon
composite flight hardware are all monitored, in real time,
during the load testing. Using PAC
software locations of active areas
are determined, whether they are on
the surface or within the structural or
mechanical components of the flight
Proof Testing and Structure
Integrity of Aircraft
PAC has been a leader in this area
since the mid-80’s, when AE was suc-
cessfully applied to the F-111 Cold
Proof Fatigue Testing that is still
used worldwide today.
Acoustic Emission is also utilized in
static frame/member load testing performed in a test facil-
ity or hangar facility to confirm design integrity and fitness
for service. This is done full scale on entire aircraft or key
areas in the initial design stage and during aircraft lifetime.
Aircraft Full Scale Fatigue Test (FSFT)
Present nondestructive inspection (NDI) techniques such as
ultrasonics, eddy current, and radiography require highly
trained technicians, time-consuming searches of broad areas,
and often significant disassembly of airframe structures in
order to identify crack locations and lengths. The use of AE
focuses holistic inspection on locations identified globally and
located as flaws. AE is currently being utilized to determine
the flight worthiness of certain aircraft designs.
Halon Bottle Recertification System
The Halon Bottle Recertification System (HBRS) is a dedicated
product, designed for testing Halon 1301 fire extinguisher
spheres from 5 to 16 inches in diameter. Conceptually devel-
oped by the Sandia National Laboratory, funded by FAA’s aging
aircraft initiative and fully developed by Physical Acoustics
Corporation (PAC), the system consists of state-of-the-art
Acoustic Emission (AE) instrumentation and application-spe-
cific software.
Offering significant advantages over the traditional method,
the HBRS detects smaller and more damaging “crack-like”
flaws, as well as interior corrosion. As the temperature rises
in the test chamber, stress in the metal wall is increased
above normal service pressure. This results in the emission
of stress waves indicative of minute
flaws/corrosion within the bottle.
The system detects and analyzes
these waves to provide a pass/fail
The greatest financial advantage
resulting from this test procedure
is in decreased bottle handling.
After removal from the aircraft, the
Halon bottle is recertified immedi-
ately and returned to the aircraft.
Significant cost savings are gained
from a reduction of inventory and
inventory-related record keeping
because the Halon is not removed
from the container. Depending on the size of the bottle, the
actual test procedure takes an average of only 30 minutes.
The Halon Bottle Recertification System has a stainless steel, roll out
shelf capable of holding Halon bottle and fixture up to 200 lbs.
A representation of the NASA X-37 Flaperon upon re-entry.
A fighter aircraft being readied for a full-scale fatigue
test using AE monitoring.
Physical Acoustics Corporation, NDT Automation, Vibra-Metrics
AE detection of defects in helicopters during operation.
Industrial UT Systems
NDTA’s Industrial Ultrasonic Immersion Systems product line
includes a variety of product sizes, all designed to provide a
rugged solution for the inspection of metallic or nonmetallic
components of all geometries in harsh industrial environ-
ments. The 48” Industrial 6 axis scanner shown is a high
speed, full contour following, stainless steel tank assembly.
Applications include, billet, plate, radome and other specialty
composite parts inspection. Rugged, precise and fast!
To scan flat plate fast use our very large 30’ x 12’ high speed
flat plate scanner. Full XYZGG servo motor silky smooth
automation, automatic cluster defect detection and sizing.
Production 24/7 ready with belt driven linear rails and closed
loop servo drive motion system. This system is a proven aero-
space metals supplier work horse. Design goal: save money
and ensure quality.
Our heavy duty missile scanner was developed for the mili-
tary. Utilizing squirter technology, this portable (breaks down
at dry dock) turnkey system detects propellant delaminating
in the VLA burn stage.
The precision bar stock rotator was specifically designed
to quickly inspect aerospace tubing (metals and composite)
components. An environmentally protected data acquisition
system (DAS), the bar rotator has rugged industrial con-
struction, servo drive motion control and long life and zero
maintenance linear drives. It has been designed for 20 years
productive service.
The 48” Industrial 6 axis scanner is a high speed, full contour
following, stainless steel tank assembly and UltraWin Software
inspects a vast array of aerospace parts and components.
Acousto-Ultrasonic Aerospace Solutions
Pocket AU
is a computerized hand-held Acousto- Ultrasonic
(AU) imaging system that is used in conjunction with a rolling
sensor for nondestructive inspection of composite materials
and other materials/structures that are difficult to inspect
with “Plain” UT or other NDT
The system is ideal for de-
tecting damaged areas in
graphite- graphite composite
thin panels (0.125”) and its
portable scanner is capable
of producing C-Scan images
with a resolution of 0.0625
in along the rolling direction
and 0.125 in along the step-
ping direction. The Pocket
AU also detects impact and
thermal damaged areas in
composite aircraft skin.
Ultrasonic (UT)
Aerospace Solutions
NDT Automation: Innovation, Expertise and Quality...
NDT Automation (NDTA) offers a full range of Ultrasonic inspec-
tion systems designed to service the diverse Aerospace testing
markets. From fully automated industrial C-Scan systems for
flat plate, forging and specialty composites inspection to por-
Pocket AU rapidly supplies full C-Scans of areas of without the need for
complex X-Y mechanical scanners.
The Pocket AU
hand-held unit
houses a complete Acousto-Ultra-
sonic subsystem.
table mini scanners for use on in-service aerospace structures.
NDT Automation has been developing UT systems for over 28
years. During this time, our Ultrasonic business has grown
from designing and manufacturing premier Ultrasonic system
cards to our present state of supplying precision, industrial
high speed scanning systems.
Our comprehensive components product line includes full
Windows XP, A/B/C-Scan software with RF storage, cluster-
ing and 3D image displays. We also offer a full range of PCI
system cards including our AD-IPR-1210 integrated 100 MHz,
12-bit digitizer/30 MHz pulser receiver, whose capabilities in
accuracy and speed cannot be matched.
NDTA is not another systems integrator. We design AND manu-
facture all the major components of our system’s in-house
and thus, have total control over specifications, costing and
system performance.
Members of MISTRAS Group Inc.
Precision UT Systems
In ultrahigh resolution re-
quirements, the Mini-Sam
ultrasonic microscope de-
livers with a staggering 50
– 125 MHz bandwidth. This
high resolution system is
designed to resolve almost
any avionic or thin ceramic
application customer need.
NDT Automtion has a European
approved contour follow-
ing system. With Ultrawin

Software’s full-featured 5
axis contour following pack-
age. Complex curves are just
a few mouse clicks away!
Teach and learn or CAD file.
Traditional Scanner or Gantry choose!
Portable UT
The Pocket UT

i s the wor l d’s
first (and only)
ba t t e r y - o pe r -
ated, hand-held,
stand-alone, full
C-Scan (A & B Also
available) data ac-
quisition system.
With its portabil-
ity and ease of use
coupled with its
full C-Scan capabil-
ity, the Pocket UT system (along with its available companion
scanners - or other compatible devices) is ideal for on-site
inspection applications. It quickly assesses the presence,
depth, shape and orientation
of cracks, flaws, corrosion/
erosion, delaminations, and
internal anomalies in a vari-
ety of aerospace structures,
materials and surfaces.
The Pocket UT is a two-
pound, hand-held Windows
CE based real time A,B,C-
Scan system. It is compatible
with contact, dry coupled
Z-scanner or our 2 axis scan-
With its portability and ease
of use coupled with its full C-
Scan capability, the Pocket UT
system (along with its avail-
able companion scanners - or other compatible devices) is
ideal for on-site inspection applications. It quickly assesses
The precision bar stock rotator was specifically designed to
quickly inspect aerospace tubing (metals and composite)
Very large 30’ x 12’ high speed flat plate ultrasonic scanner. Mul-
tiple scanning transducers speed up operation.
NDTA’S Mini-SAM Ultrasonic Microscope delivers with a staggering
50 – 125 MHz bandwidth.
Next stop Mars! Chemically etched, Kevlar
wrapped fuel cell under UT bond inspection.
Heavy duty ultrasonic missile scanner utilizes squirter technology.
Physical Acoustics Corporation, NDT Automation, Vibra-Metrics
the presence, depth, shape and orientation of cracks, flaws,
corrosion/erosion, delaminations, and internal anomalies in
a variety of structures, materials and surfaces.
UT Scanners and Components
NDT Automation designs and manufactures a variety of manual
and automated scanners. Our Z-Scan is a dry-coupled (roll-
ing dual-element transducer) scanner, not much bigger than
a computer mouse, that uses a unique encoder design to
produce an accurate raster-type C-Scan image. The scanner
is coupled with a Pocket UT system or a conventional, por-
table PC-based system, such as our MicroSonic (with notebook
PC), to provide full C-Scan (with B-Scan) data acquisition
capabilities. With minimum attainable resolutions as small
as .010 inches (.25 mm), the Z-Scan operates with various
surface geometries such
as plates and difficult to
reach areas.
The MS - XY- 2 i s a
dual-rectilinear axis
manual scanner designed
to inspect flat to gen-
tly curving surfaces. It
includes a “universal
mount” for positioning
transducers of virtually
any shape or geometry.
This scanner includes
both magnetic and suction cup mounting capability. When
interfaced to UltraWin™ Ultrasonic inspection software, the
MS-XY-2 can be configured to scan or index on either axis and
produces full 2-D/3-D C-Scan inspection images. Each axis
can be individually “locked” in place (and released) by the
user. Cables and connectors to interface with the host system
scanner interface card (required for communication with any
PC-based Ultrasonic Inspection System Host) are included.
It also comes in an automated version that features a high
speed stepper-motor driven in excess of 7 inches (175 mm)
per second.
Dual-axis, dry-coupled scanner connects
directly into the hand-held Pocket UT
System for full C-Scan data acquisi-
C-Scan of next generation aircraft com-
posite structure using the Pocket UT.
UT Boards
From our 1 GHz digitizer, 100 MHz combination dig-
itizer and ultra low noise pulser receiver to the
precise SMC-8 eight axis smart motion control high
performance, step-
per mot or and
encoder interface
boar d and our
ARB-1412 arbitrary
waveform card for
guided wave thick
section composites
inspection, NDTA’s
full-line of UT PCI
system boards are
designed and built
UT Accessories
To a u g m e n t o u r l i n e o f u l t r a s o n i c
systems, we produce key accessory items for specific applica-
tions and to enhance system performance. These include the
(MicroSonic) UT System, which permits our systems
to operate with a notebook computer and an external set of
With no cumbersome guides, frames or
other scanner structural elements to
get in the way, and no need for liquid
or gel couplant, the scanner sets up very
quickly in the field.
UT PCI boards and associated software.
Manual and motorized 2 axis scanners.
Mount either right to the structure under
test. 0 to full color C-Scan in minutes.
The Pocket UT System comes complete with hand-held unit,
transducer, cables, battery charger & couplant.
Members of MISTRAS Group Inc.
Corporate Hqts: 195 Clarksville Road, Princeton Jct., NJ • Phone: (609) 716-4000 • Fax: (609) 716-0706 • email:
Subsidiaries: Athens: • Beijing: • Buenos Aires • Cambridge:
Hamburg: • Moscow: • Paris: • Rotterdam:
Sao Paulo: • Tokyo: Representatives: Worldwide • •
Copyright © 2006 MISTRAS Group Inc. All Rights Reserved. #44-06
MISTRAS Group Inc. Worldwide Offices - Serving the Aerospace Industry
MISTRAS Group Inc.
MISTRAS Group Inc. is comprised of MISTRAS Services, MISTRAS Products and 10+ wholly-owned international subsidiaries. Members of MIS-
TRAS Services, include CONAM QSL-Plus, & Code Services, which provide a complete range of inspection, training, QA/QC and proprietary
Plant Condition Monitoring Software (PCMS). Members of MISTRAS Products include, Physical Acoustics Corporation (PAC), NDT Automation and
Vibra-Metrics. As the recognized leader in acoustic emission (AE) technology, PAC designs, manufactures and markets AE sensors, systems and
software for laboratory and on-line industrial clients through its network of worldwide subsidiaries. NDT Automation offers high-end ultrasonic
imaging equipment and systems to a wide array of industrial applications. Vibra-Metrics offers vibration sensors, instruments and on-line plant
asset integrity management systems for Internet/intranet based predictive maintenance.
All members of MISTRAS Group Inc. are supported by the Research, Engineering, Applications, Certification, and Training (REACT) group, which
is a Research and Development team that produces innovative solutions to solve industrial problems worldwide.
With a global network of locations employing over 1,000 engineers, PhD’s, certified technicians, software designers and QA/QC professionals,
MISTRAS Group Inc. has experience with all types of Aerospace testing requirements. With a complete line of products, engineering services,
R&D and proprietary On-line Asset Integrity Management Internet/Intranet software, we strive to be Your Total Aerospace NDT Solutions
ultrasonic and motion control cards as
well as a “stackable” multiplexer that
can be configured from 4 through 128
channels of operation. The µSonic

enhances the portability of our sys-
tems, while the multiplexer permits
lower-cost operation of multiple chan-
For over thirty years, Vibra-Metrics
has supplied innovative and pat-
ented solutions for Aerospace and the
predi cti ve mai ntenance com-
munity, even in the most advanced or demanding
application. Since our inception, we have grown to offer
hundreds of quality products including vibration accelerom-
eters, on-line data delivery systems such as our patented
Sensor Highway
and a comprehensive assortment of ancil-
lary products.
Vibra-Metrics takes a con-
ditions-drive approach to
sensing product selection,
providing a full range of ac-
celerometers to suit almost
any condition or applica-
tion. Our accelerometers
and vibration sensing equip-
ment rank among the best in
the industry. The company
leads the industry in the
development of exclusive features
such as integral cable assemblies and
electronics, as well as a wide range of
frequencies that are well suited to per-
manent installation in the Aerospace
industry. With a renewed emphasis in
advanced accelerometer designs and
quality, Vibra-Metrics leads the way
in today’s most demanding Aerospace
Sensor Highway – Asset Integrity
Management and Condition
Based Monitoring System
Vibra-Metrics built the patented Sensor Highway
that is ideal for Asset Integrity Management and overall
condition monitoring. It provides industrial assets managers
with a low-cost, modular solution for achieving advanced
on-line monitoring of critical equipment parameters such
as vibration, temperature, pressure, and almost any other.
The expandable Sensor Highway System offers advantages
over traditional predictive maintenance programs such as
increased data collection frequency, more repeatable/ac-
curate data, easier trending analysis, and more efficient
use of your PdM staff. The bottom line? A PdM system
that can return up to five times the investment in a short
period of time.
Notebook driven µSonic
(MicroSonic) UT
Scanning System.
Vibra-Metrics offers a complete
line of accelerometers and inte-
gral drive electronics.