Integrated Non-Destructive Testing for Assessing Manufacturing Defects in Melt-Fusion Bonded Thermoplastic Composite Pipes

The thermoplastic composite pipe (TCP) manufacturing process introduces defects that impact performance, such as voids, misalignment, and delamination. Consequently, there is an increasing demand for effective non-destructive testing (NDT) techniques to assess the influence of these manufacturing defects on TCP. The objective is to identify and quantify internal defects at a microscale, thereby improving quality control. A combination of methods, including NDT, has been employed to achieve this goal. The density method is used to determine the void volume fraction. Microscopy and void analysis are performed on pristine samples using optical micrography and scanning electron microscopy (SEM), while advanced techniques like X-ray computer tomography (XCT) and ultrasonic inspections are also applied. The interlayer between the reinforced and inner layers showed good consolidation, though a discontinuity was noted. Microscopy results confirmed solid wall construction, with SEM aligning with the XY axis slice, showing predominant fibre orientation around ±45° and ±90°, and deducing the placement orientation to be ±60°. Comparing immersion, 2D microscopy, and XCT methods provided a comparative approach, even though they could not yield precise void content values. The analysis revealed a void content range of 0–2.2%, with good agreement between microscopy and Archimedes’ methods. Based on XCT and microscopy results, an increase in void diameter at constant volume increases elongation and reduces sphericity. Both methods also indicated that most voids constitute a minority of the total void fraction. To mitigate manufacturing defects, understanding the material’s processing window is essential, which can be achieved through comprehensive material characterization of TCP materials.