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Technical Discussions
Laurie Shopes
Laurie Shopes
05:30 Feb-01-2000
NDT of Polyurethane Foam

I work for Delphi Interior Systems near Dayton, Ohio. We make
Instrument panels (dashboards) for automobiles using an injection
molding process. This process involves injecting a polyurethane
foam between layers of vinyl and a hard plastic shape retainer.
When the parts are made, especially in the prototype stage, there
are often voids in the foam that may not be detected by the eye
or touch. I am looking for a way to detect the voids non-
destrictively before shipping the parts to the customer. Ideally,
I'd like to find a way to scan the parts and be able to create a
mapping of where the voids occur, and how large they are.
Typically, the voids that cause problems are anywhere from 7-10mm
to a large hole that runs along the length of the part. Please
let me know any ideas you may have, or if your company provides
services and equipment to perform these tests.
Thank you,
Laurie Shopes
Delphi Interior Systems



    
 
 
Trevor Easton
Engineering
Dofasco Inc, Canada, Joined Nov 1998, 13

Trevor Easton

Engineering
Dofasco Inc,
Canada,
Joined Nov 1998
13
05:58 Feb-01-2000
Re: NDT of Polyurethane Foam
If you can scan the parts immediately after forming you may be able to detect the voids using a thermographic camera. The heating of the foam during expansion may reveal voids as cooler areas on the surface.


: I work for Delphi Interior Systems near Dayton, Ohio. We make
: Instrument panels (dashboards) for automobiles using an injection
: molding process. This process involves injecting a polyurethane
: foam between layers of vinyl and a hard plastic shape retainer.
: When the parts are made, especially in the prototype stage, there
: are often voids in the foam that may not be detected by the eye
: or touch. I am looking for a way to detect the voids non-
: destrictively before shipping the parts to the customer. Ideally,
: I'd like to find a way to scan the parts and be able to create a
: mapping of where the voids occur, and how large they are.
: Typically, the voids that cause problems are anywhere from 7-10mm
: to a large hole that runs along the length of the part. Please
: let me know any ideas you may have, or if your company provides
: services and equipment to perform these tests.
: Thank you,
: Laurie Shopes
: Delphi Interior Systems




    
 
 
Rich Martin
Rich Martin
06:17 Feb-01-2000
Re: NDT of Polyurethane Foam
You may want to consider low frequency air coupled
ultrasonics as an option. The low frequency allows
through transmission inspection of highly attenuating
materials such as honeycomb structures or as in your
case, foam. I'm not sure if such a system can meet
your flaw size requirements, but it is a relatively
inexpensive method.


: I work for Delphi Interior Systems near Dayton, Ohio. We make
: Instrument panels (dashboards) for automobiles using an injection
: molding process. This process involves injecting a polyurethane
: foam between layers of vinyl and a hard plastic shape retainer.
: When the parts are made, especially in the prototype stage, there
: are often voids in the foam that may not be detected by the eye
: or touch. I am looking for a way to detect the voids non-
: destrictively before shipping the parts to the customer. Ideally,
: I'd like to find a way to scan the parts and be able to create a
: mapping of where the voids occur, and how large they are.
: Typically, the voids that cause problems are anywhere from 7-10mm
: to a large hole that runs along the length of the part. Please
: let me know any ideas you may have, or if your company provides
: services and equipment to perform these tests.
: Thank you,
: Laurie Shopes
: Delphi Interior Systems




    
 
 
Norm Woodward
Norm Woodward
05:11 Feb-03-2000
Re: NDT of Polyurethane Foam
: You may want to consider low frequency air coupled
: ultrasonics as an option. The low frequency allows
: through transmission inspection of highly attenuating
: materials such as honeycomb structures or as in your
: case, foam. I'm not sure if such a system can meet
: your flaw size requirements, but it is a relatively
: inexpensive method.

:
: : I work for Delphi Interior Systems near Dayton, Ohio. We make
: : Instrument panels (dashboards) for automobiles using an injection
: : molding process. This process involves injecting a polyurethane
: : foam between layers of vinyl and a hard plastic shape retainer.
: : When the parts are made, especially in the prototype stage, there
: : are often voids in the foam that may not be detected by the eye
: : or touch. I am looking for a way to detect the voids non-
: : destrictively before shipping the parts to the customer. Ideally,
: : I'd like to find a way to scan the parts and be able to create a
: : mapping of where the voids occur, and how large they are.
: : Typically, the voids that cause problems are anywhere from 7-10mm
: : to a large hole that runs along the length of the part. Please
: : let me know any ideas you may have, or if your company provides
: : services and equipment to perform these tests.
: : Thank you,
: : Laurie Shopes
: : Delphi Interior Systems

If you decide to look into low frequency, air-coupled devices, one source that I am aware of is NDT Systems of Huntington Beach CA. As I recall, their Curlin Air system has originally developed for the inspection of foam structures.

They can be reached at 714-893-2438, or thru their web site at www.ndtsystems.com.

Norm


    
 
 
J. Mark Davis
Teacher, And Consultant
University of Ultrasonics, Birmingham, Alabama, USA, Joined Mar 2000, 85

J. Mark Davis

Teacher, And Consultant
University of Ultrasonics, Birmingham, Alabama,
USA,
Joined Mar 2000
85
04:14 Feb-05-2000
Re: NDT of Polyurethane Foam
Dear Laurie,

I see you are at GM Delphi in Dayton. One of the NDT Process would be an automated ot semi-automated digital radiography system. I scanned some radiographs for a Tom Clark at Delphi last month. He can show you some of the digital images using our software. There in Dayton, you should contact Mr. Dennis Lee at US Inspection/Dayton X-ray. They will be able to help you out. (937) 228-9729.

You critical flaw size would not be a problem with digital radiuography. With the digitzed radiographs I can size flaws around 0.010 using geometric enlargment and using a calibrated RT ruler within the software.

Your parts would be put on a
tread mill and the parts would be moved through an X-ray system to greatly speed production. You could sample the parts or run them all.

Please email me if you have any other questions. The others who responded with Low freq. Ut and Thermograpgy are also very viable NDT methods.

As for cost I do not know.

Good Luck,

J. Mark Davis

: I work for Delphi Interior Systems near Dayton, Ohio. We make
: Instrument panels (dashboards) for automobiles using an injection
: molding process. This process involves injecting a polyurethane
: foam between layers of vinyl and a hard plastic shape retainer.
: When the parts are made, especially in the prototype stage, there
: are often voids in the foam that may not be detected by the eye
: or touch. I am looking for a way to detect the voids non-
: destrictively before shipping the parts to the customer. Ideally,
: I'd like to find a way to scan the parts and be able to create a
: mapping of where the voids occur, and how large they are.
: Typically, the voids that cause problems are anywhere from 7-10mm
: to a large hole that runs along the length of the part. Please
: let me know any ideas you may have, or if your company provides
: services and equipment to perform these tests.
: Thank you,
: Laurie Shopes
: Delphi Interior Systems




    
 
 

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