The FlawExplorer is a laser shearography non-destructive testing (NDT) sensor designed to be used for post-production quality control applications or in-field component inspections. The sensor can be configured with thermal or vacuum (partial) excitation systems depending on the application and additionally may be automated. The FlawExplorer incorporates the very latest in phase-shifting technology, delivering accurate and reliable measurement results through clear and sharp imaging with sub-micrometer displacement resolution.

The FlawExplorer sensor is completely contained in one lightweight (5 kg/11 lb) unit. Only two connections are required to operate the sensor; one for power and one for camera data. With fully integrated imaging & control electronics, the sensor incorporates a (standard) 3.2 MPx or (optional) 5 MPx, CMOS camera with maximum frame rate of 37 & 24 Hz, respectively, a varifocal zoom lens, eight (Class 3R) laser diodes, automatic shearing and phase-shifting piezos. The sensor is contained in an aluminium-housing with detachable safe-guard ring. The rugged design of the FlawExplorer is designed to withstand shocks, knocks and vibrations.

Laser Shearography has one of the highest inspection rates compared to any NDT method, specifically because it utilizes a large Field-of-View (FoV) from the use of multiple coherent laser diodes. A FlawExplorer uses 8 laser diodes to generate a large illumination area and FoV. For a standard 3.2 MPx camera, an achievable projected image size in one shot can be up to 2.9 m x 2.1 m (9.4 ft x 7.0 ft) or for an optional 5.0 MPx camera, up to 3.4 m x 2.8 m (11.2 ft x 9.3 ft). The inspection speed of the FlawExplorer is unmatched compared to any other NDT technique, delivering high throughput rates for time-saving inspections.

A FlawExplorer system can be completely automated, including camera and heat triggering, display settings, filters and control parameters. Whether mounted on a robotic arm, linear traverse, or an XY gantry, the sensor uses a dedicated communication protocol allowing complete interaction between the FlawExplorer software, Istra4D, and an autonomous PLC interface. Numerous successful automation projects for diverse NDT applications of Laser Shearography have driven the normalized requirement for robotic integration. This possibility is now available as a standard software module option, for complete reproducible testing.

Istra4D, Dantec Dynamics’ advanced laser shearography software, is intuitive and simple to use. With a clear user workflow, users have easy control of all relevant measurement configuration parameters, including brightness, shearing, projection, and visualization settings. Users can easily perform real-time measurements and also advanced post-processing analysis of acquired results. Whatever the NDT application, Istra4D is the imaging workhorse behind all of Dantec’s laser shearography systems.