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Modeling of small carbon fiber-reinforced polymers for X-ray imaging simulation

A methodology for generation of realistic three-dimensional software models of carbon fiber-reinforced polymer (CFRP) structures, dedicated for use in simulation studies of advanced X-ray imaging techniques for non-destructive testing (NDT), has been developed, implemented, and evaluated. Two CFRP models are presented in this paper, one built as a set of stacked layers that contain continuous carbon bundles and a second as a braided textile from woven carbon bundles. The following CFRP defects were modeled: porosity, missing carbon bundles, and non-carbon inclusions. X-ray projection images were generated using an in-house developed X-ray imaging simulator. The obtained preliminary visual and quantitative validation results showed an overall good correlation of characteristics between synthetic and experimental data radiographs and justify the use of this model for research in CFRP X-ray imaging. The application of the CFRP model is demonstrated in a feasibility study that aims to computationally evaluate the appropriateness of two advanced X-ray imaging techniques: cone-beam CT (CBCT) and tomosynthesis (limited arc tomography), as inspection techniques for NDT of CFRP parts. The simulation showed that in all cases the CBCT approach outperformed both conventional radiography and tomosynthesis in terms of defect characterization and visualization.