Polarized Light Detection of Flaws in Aerospace Transparency Heating Elements
Polarized Light Detection of Flaws in Aerospace Transparency Heating Elements
Polarized Light Detection of Flaws in Aerospace Transparency Heating Elements
for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
INTRODUCTION
Electrically conductive coatings used in aerospace transparencies for heating purposes may contain
flaws resulting from imperfections of materials, imperfections of manufacturing techniques, handling
damage, or contamination. Flaws may develop before, during, or after coating and processing and
usually appear as hairline cracks, scratches, or pin holes. When these flaws are of sufficient size, hot
spots can occur as a result of disruption and concentration of the flow of electrical current adjacent to
the flaws. These hot spots may result in reduced service life of the transparency. Hot spot flaws in the
transparency may also produce undesirable temporary distortion of vision during powered operation
of the heater and permanent vision distortion after repeated cycling of the heater.
Polarized light is widely used to detect electrically conductive coating flaws during aerospace
transparency processing.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
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are limited to those that produce temperature gradients when adjusted during inspection so that the light path is within 20° of
electrically powered. Any other type of flaw, such as minor normal to the location being viewed. Since specimen size and
scratches parallel to the direction of electrical flow, are not curvature vary considerably, a dimensionally fixed standard is
detectable. not given.
5. Apparatus 5.2 The apparatus, in the order of assembly, consists of the
following:
5.1 The elements of the apparatus are detailed below in their
physical relationship as shown in Fig. 1. The minimum size 5.2.1 Uniform Light Source, such as a bank of fluorescent
and spacing of the elements of the apparatus are determined by lamps.
the size and curvature of the part. The size of light source, light 5.2.2 Translucent Light Diffusion Plate, such as milk-white
diffuser, and polarizing screen shall be large enough so that glass located so as to provide a uniform light distribution.
every portion of the electrically coated area of the test 5.2.3 Polarizing Screen, which converts the diffused light to
specimen is in the light path and is uniformly back-lit. If the polarized light.
test specimen is curved severely, its position may have to be 5.2.4 Transparent Dust Shield (optional).
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5.2.5 Support for the specimen. exist before power is applied. Mark all defect locations. The
5.2.6 Polarizing Viewer, hand-held or mounted so it can be object of this step is to record defects that are unrelated to the
rotated to give maximum contrast as an analyzer. energized conductive coating.
5.2.7 Electrical Power Supply, regulated. 10.3 Power Application—With the specimen stabilized at
5.2.8 Timer, for controlling power application. room temperature, apply the minimum voltage levels defined
5.2.9 Meters, for measuring power input to heater element. below for a period required to achieve a visually identifiable
6. Safety Precautions pattern of flaws. Apply voltage suddenly, by closing a switch.
Do not use a gradual change in voltage.
6.1 This practice may require application of high voltages.
Exercise precautions to prevent direct or indirect exposure of NOTE 1—Care should be taken to limit application time to prevent
overheating, which could occur in a few seconds.
test personnel to terminals, test leads, and so forth.
10.3.1 For electrically conductive coatings on plastic
6.2 Wear protective glasses to prevent damage to eyes by
materials, apply a minimum of 110 % of the nominal design
flying glass particles which may be generated by shattering
voltage.
from thermal shock or handling when glass parts are tested.
10.3.2 For electrically conductive coatings on glass, apply a
7. Sampling minimum of 125 % of the nominal design voltage.
10.3.3 Alternative voltage levels and power-on times may
7.1 When specified for use as a final acceptance procedure, be as specified by contractual documents.
all deliverable electrically heated transparencies will be tested
in the final laminated condition for heater element flaws. 10.4 Watch through the viewer for flaws, which appear
during the power cycle as intense and localized areas of light
7.2 Heater elements may be tested prior to lamination of the or shadow. Rotate the viewer for maximum contrast.
assembly to screen out defective or marginal electrical conduc-
tive coatings. NOTE 2—The flaws are most pronounced immediately after the appli-
cation of power. Flaws, depending on cause, produce star, cross, or
8. Test Specimen butterfly-shaped light patterns. The highest practical electrical power level
produces the strongest image.
8.1 The test specimen shall be a full-size monolithic or NOTE 3—Preliminary experimentation with instrumented specimens
laminated part as specified in drawings that detail materials and containing typical flaws may be required to establish the power levels and
dimensions. The test specimen shall be complete and full scale durations required for maximum image strength without overheating.
with respect to contour, conductive coating, deletion lines, 11. Interpretation of Results
bus-bars, temperature sensing elements, electrical connections,
11.1 After application of power and when viewed from the
and any other permanent electrical functional parts or elements
eye position, record every flaw that appears in the primary
affecting the electrical flow direction or magnitude anywhere
viewing area (as defined by the part drawing).
within the active portion of the conductive coating.
11.2 If an eye position is not defined, view the entire heated
8.2 The test specimen need not have final fabrication details
area from a distance of approximately 1.5 m. Mark all flaw
such as reinforcement bonding, trimming, drilling of edges,
locations and describe them by size, shape, and location.
and so forth, provided that the incomplete fabrication does not
affect the heating pattern and maximum temperatures of the 12. Report
electrically conductive coating. 12.1 When required by the customer, a report shall be
8.3 The final inspection of a laminated part shall be con- prepared for all specimens considered satisfactory for further
ducted only when all elevated temperature adhesive and cure processing or delivery.
cycles have been completed and the part temperature has 12.2 The report shall be a record showing the locations,
returned to ambient room temperature. sizes, and shapes of all minor heating element flaws that
9. Preparation of Apparatus appeared during power application. The dimensional record
may be a drawing, a photo of the marked up specimen, or a
9.1 Install the test specimen in relation to the test apparatus photo of the specimen under lighted conditions. The report
as shown in Fig. 1. Position the specimen so that it is parallel shall include a record of the setup, test procedures, test
to the polarizing screen. equipment used, and any other data required to confirm the use
9.2 Connect the power leads to the specimen. of appropriate equipment and procedures and all data required
9.3 If the part is severely curved, make provisions for for verification of the quality of the part.
adjustment of the part relative to the polarizing apparatus such 13. Precision and Bias
that the viewing angle does not deviate more than 20° from
13.1 No statement is made about either precision or bias,
normal to the surface of the uniform light source diffuser plate.
since the result merely establishes the detection of flaws
10. Procedure without specifying an acceptable criteria.
10.1 Turn on the polarized light source. 14. Keywords
10.2 Visually survey the test specimen at a distance of 1.5 14.1 coatings; conductive coatings; heating elements; polar-
m, using the polarizing viewer to determine defect patterns that ized light; polarized light inspection
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