Joint inspection system and method of inspecting joints in a structure

Abstract

The invention relates to a joint inspection system and a method of inspecting a joint in a structure. In one method, an ion beam source sends an ion beam into a first surface of a structure with an ion beam to form an acoustic pulse source at a depth in the structure corresponding to a Bragg peak of the ion beam, wherein the acoustic pulse source is proximate to a joint. A propagation time and a magnitude of an acoustic pulse generated by the acoustic pulse source are sensed by an acoustic sensor located at a second surface of the structure, thereby forming a response, wherein the joint is located between the acoustic pulse source and the second surface.

Description

Technical Field

[0001] This disclosure generally relates to non-destructive testing, and more specifically to the inspection of joints in structures. Background Technology

[0002] Welding and adhesives are common methods for joining objects. When joining objects, a joint is formed at the interface between them. The joint between two objects can be tested or inspected to verify its strength. However, it is difficult to detect unbonded portions of a joined joint or voids in the weld.

[0003] Therefore, it is desirable to have a method and apparatus that take into account at least some of the problems discussed above, as well as other possible problems. Summary of the Invention

[0004] This illustrative embodiment provides a method for inspecting a joint in a structure. An ion beam is delivered from an ion beam source to a first surface of the structure to form an acoustic pulse source at a depth in the structure corresponding to the Bragg peak of the ion beam. The acoustic pulse source is adjacent to the joint. A response is generated by sensing the propagation time and magnitude of the acoustic pulse generated by the acoustic pulse source by an acoustic sensor located on a second surface of the structure, wherein the joint is located between the acoustic pulse source and the second surface.

[0005] Another illustrative embodiment of this disclosure provides a connector inspection system. The connector inspection system includes: an ion beam source; and an acoustic sensor positioned to receive acoustic pulses formed by the energy of an ion beam originating from the ion beam source.

[0006] Another illustrative embodiment of this disclosure provides a method for inspecting a joint in a structure. An ion beam is repeatedly delivered to a first surface of the structure to form an acoustic pulse source within a first portion of the structure located on a first side of the joint. The propagation time and magnitude of the acoustic pulse generated by the acoustic pulse source are sensed at a second surface of a second portion of the structure, thereby forming a response. The joint is the interface between the first and second portions of the structure. Based on the response, it is determined whether an inconsistency exists in the joint.

[0007] These features and functions may be implemented independently in various embodiments of this disclosure, or may be combined in other embodiments, more details of which can be seen with reference to the following description and accompanying drawings. Attached Figure Description

[0008] The appended claims set forth novel features that are considered essential to the illustrative embodiments. However, the illustrative embodiments and their preferred modes of use, further objects and features, will be best understood by referring to the following detailed description of the illustrative embodiments of this disclosure, in conjunction with the accompanying drawings:

[0009] Figure 1 This is a block diagram illustration of the inspection environment of the operating connector inspection system according to an illustrative embodiment;

[0010] Figure 2 This is an illustration of a cross-sectional view of the joint during an inspection according to an illustrative embodiment.

[0011] Figure 3 It is a diagram of the intensity curve of the response from the joint inspection according to the illustrative embodiment;

[0012] Figure 4 This is a flowchart illustrating a method for inspecting joints in a structure according to an illustrative embodiment;

[0013] Figure 5 This is a flowchart illustrating a method for inspecting joints in a structure according to an illustrative embodiment;

[0014] Figure 6 It is an illustration of an aircraft manufacturing and maintenance method in block diagram form according to an illustrative embodiment; and

[0015] Figure 7 This is a block diagram of an aircraft in which illustrative embodiments can be implemented. Detailed Implementation

[0016] The illustrative embodiments recognize and take into account one or more different considerations. The illustrative embodiments recognize and take into account that certain joints or connections cannot currently be verified using conventional non-destructive testing methods. The illustrative embodiments recognize and take into account that the penetration distance of X-rays is insufficient to verify joints in large structures. The illustrative embodiments recognize and take into account that the penetrating power of X-rays is limited in dense materials. Another limitation of X-ray inspection, unless tomographic imaging techniques are used, is the undesirable low depth resolution. However, tomographic imaging techniques increase processing time.

[0017] The illustrative embodiments acknowledge and take into account that the ultrasonic sensitivity and resolution for thick objects may be undesirably low. The illustrative embodiments also acknowledge and take into account that ultrasonic sensitivity and resolution may depend on the material of the structure.

[0018] The illustrative embodiments recognize and consider that, in conventional ultrasonic testing, a transducer generates acoustic pulses at a surface. The acoustic energy initially propagates along a direct path. If there are no inconsistencies in the weld or joint, these direct paths lead directly to the acoustic sensor on the other surface. If there are inconsistencies in the weld or joint, the acoustic path cannot lead directly to the sensor. Instead, the dispersed acoustic energy from the inconsistencies reaches the sensor, resulting in an intensity profile that is not significantly different from an acceptable profile. The physical characteristics of this situation limit the sensitivity to inconsistencies in conventional ultrasonic testing.

[0019] For ultrasound examinations, transducers can be used to enhance at least one of ultrasound sensitivity or resolution. The illustrative embodiments acknowledge and take into account that the use of transducers increases cost and labor. Furthermore, ultrasound examinations may be unable to verify certain combinations of materials, shapes, and thicknesses.

[0020] Now go to Figure 1 The diagram illustrates a block diagram of an inspection environment for an operational connector inspection system, based on an illustrative embodiment. The connector inspection system 100 in the inspection environment 102 is configured to inspect the connector 104 of the structure 106. The connector inspection system 100 includes an ion beam source 108 and an acoustic sensor 110. The ion beam source 108 is oriented toward the acoustic sensor 110. The acoustic sensor 110 is positioned to receive acoustic pulses 112 formed by the energy of an ion beam 114 originating from the ion beam source 108.

[0021] The kinetic energy 120 in the ion beam 114 is deposited over a short distance within structure 106. The kinetic energy 120 is converted into heat energy, which causes thermal expansion within the acoustic pulse source 126. The thermal expansion of the acoustic pulse source 126 generates an acoustic pulse 112.

[0022] Ion beam source 108 generates ion beam 114. Ion beam 114 generates acoustic pulses 112 within structure 106. Ion beam source 108 can take any desired form. In some illustrative embodiments, ion beam source 108 is one of a cyclotron, a van der Graff generator, or a linear accelerator.

[0023] In some illustrative embodiments, the connector inspection system 100 also includes a beam steering system 116 configured to alter the shape of the ion beam 114. In some illustrative embodiments, the beam steering system 116 is optional.

[0024] In some illustrative embodiments, an attenuator 118 is positioned between the ion beam source 108 and the target of the ion beam source 108. As depicted, structure 106 is the target of the ion beam source 108. In these illustrative embodiments, the attenuator 118 is located between the ion beam source 108 and structure 106. The attenuator 118 is optional. When the attenuator 118 is present, it controls the kinetic energy 120 of the ions 122 of the ion beam 114. Control of the kinetic energy 120 of the ions 122 of the ion beam 114 allows adjustment of the depth 124 of the acoustic pulse source 126 in structure 106.

[0025] In some illustrative embodiments, the kinetic energy 120 of the ions 122 of the ion beam 114 is controlled by adjusting the ion beam source 108. In some illustrative embodiments, the ion beam source 108 is adjusted by changing the ion type 128.

[0026] In operation, ion beam source 108 delivers ion beam 114 into structure 106. Ion beam source 108 delivers ion beam 114 into a first surface 130 of structure 106 to form an acoustic pulse source 126 in structure 106 at a depth 124 corresponding to the Bragg peak 132 of ion beam 114. Depth 124 is selected to form an acoustic pulse source 126 adjacent to connector 104. In some illustrative embodiments, depth 124 is between the first surface 130 and connector 104.

[0027] The first surface 130 is part of the first portion 134 of the structure 106. The first portion 134 is joined to the second portion 136 of the structure 106 at a joint 104. The joint 104 is present at the interface 138 between the first portion 134 and the second portion 136 of the structure 106.

[0028] An acoustic sensor 110 is located at the second surface 140 of structure 106. The acoustic sensor 110 receives the propagation time 142 and magnitude 144 of an acoustic pulse 112 generated by acoustic pulse source 126, thereby forming a response 146. A connector 104 is located between the first surface 130 and the second surface 140. The connector 104 is located between the acoustic pulse source 126 and the second surface 140.

[0029] The response 146 is compared to an acceptable response 147. If the magnitude of the response 146 exceeds that of the acceptable response 147, an inconsistency is identified. For example, if there is an inconsistency 148 between the acoustic pulse source 126 and the acoustic sensor 110, the magnitude 144 may exceed the acceptable response 147. If there is an inconsistency 148 between the acoustic pulse source 126 and the acoustic sensor 110, some of the acoustic pulses 112 will be blocked by the inconsistency 148. The inconsistency 148 blocks some portions of the acoustic pulses 112, which reduces the magnitude 144 of the acoustic pulses 112 received by the acoustic sensor 110.

[0030] In some illustrative embodiments, an operator compares response 146 with an acceptable response 147. In other illustrative embodiments, processor 149 compares response 146 with an acceptable response 147.

[0031] In this illustrative embodiment, the comparison can be performed by the processor 149 using computer-implemented instructions. In some cases, the processor 149 may take the form of a hardware unit, such as a circuit system, an application-specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware unit.

[0032] As another embodiment, if there is an inconsistency 148 between the sound pulse source 126 and the sound sensor 110, the propagation time 142 may exceed an acceptable response. If there is an inconsistency 148 between the sound pulse source 126 and the sound sensor 110, the sound pulse 112 is dispersed by the inconsistency 148. The inconsistency 148 dispersing the sound pulse 112 may increase the propagation time 142 of the sound pulse 112 received by the sound sensor 110.

[0033] The connector inspection system 100 repeatedly sends an ion beam 150 into the structure 106 to inspect the connector 104. In some illustrative embodiments, the connector inspection system 100 causes the ion beam 150 to cross a first surface 130 to inspect the connector 104 at different locations in the structure 106.

[0034] In some illustrative embodiments, the connector inspection system 100 sends ion beams 150 with different kinetic energies into the structure 106. For example, the connector inspection system 100 may send a second ion beam 152 into a first surface 130 of the structure 106 via an ion beam source 108 to form a second acoustic pulse source in the structure 106 at a second depth corresponding to the Bragg peak 154 of the second ion beam 152. Before sending the second ion beam 152 into the structure 106, the kinetic energy of the ions in the second ion beam 152 modulates the second depth of the acoustic pulse source such that the second depth differs from depth 124. By sending ion beams 150 with different kinetic energies into the structure 106, different sides of the connector 104 can be tested.

[0035] An acoustic sensor 110 positioned on the second surface 140 senses the propagation time and magnitude of an acoustic pulse generated by a second acoustic pulse source, thereby forming a second response. In some illustrative embodiments, the response 146 and the second response originate from opposite sides of the interface 138.

[0036] In some illustrative embodiments, the fixture 149 holds the structure 106 during inspection. In some illustrative embodiments, the fixture 149 holds the structure 106 to be inspected between the ion beam source 108 and the acoustic sensor 110. In some illustrative embodiments, the fixture 149 is configured to hold the structure 106 to be inspected in the path of the ion beam source 108 and in acoustic contact with the acoustic sensor 110.

[0037] Figure 1 The illustration of inspection environment 102 is not intended to imply any physical or architectural limitations on the illustrative implementation. Other components besides those shown, or components that replace the shown components, may be used. Some components may be unnecessary. Furthermore, boxes are provided to illustrate some functional components. When implemented in the illustrative implementation, one or more of these boxes may be combined, divided, or combined and divided into different boxes.

[0038] For example, in some illustrative embodiments, the fastening device 149 is configured to place the structure 106 in a tensioned state. When the fastening device 149 places the structure 106 in a tensioned state, unconnected portions of the joint 104 can be detected. By placing the structure 106 in a tensioned state, the joint 104 within the structure 106 is also placed in a tensioned state. By placing the joint 104 in a tensioned state, any unconnected points at the joint 104 will widen. Widening the unconnected points enhances the dispersion of the acoustic pulse 112. By placing the structure 106 in a tensioned state, the joint inspection system 100 can more easily identify unconnected portions of the joint 104 within the structure 106.

[0039] As another embodiment, although processor 149 is depicted within inspection environment 100, processor 149 can be located anywhere desired. For example, processor 149 could be part of a computer system outside of inspection environment 100.

[0040] Now go to Figure 2 The illustration depicts a cross-sectional view of the connector during inspection, according to an illustrative embodiment. In view 200, the ion beam source 202 is located on the first side 204 of the structure 206. The ion beam source 202 is... Figure 1 The physical implementation of the ion beam source 108. The ion beam source 202 is oriented toward the structure 206.

[0041] Ion beam source 202 is configured to deliver ion beam 208 into a first surface 210 located on a first side 204 of structure 206. By delivering ion beam 208 into the first surface 210 of structure 206, an acoustic pulse source 212 is formed at a depth 214 in structure 206. Depth 214 corresponds to the Bragg peak 216 of ion beam 208. As depicted, depth 214 is between the first surface 210 and the connector 218. Depth 214 is selected to form an acoustic pulse source 212 adjacent to connector 218.

[0042] A graph 220 with Bragg peak 216 is provided to illustrate the energy loss of the ion beam 208 as it propagates through structure 206. Bragg peak 216 appears immediately before the ions in the ion beam 208 come to rest. Bragg peak 216 appears immediately before depth 214. At Bragg peak 216, most of the kinetic energy in the ion beam 208 is dissipated within a short distance in structure 206. This kinetic energy is converted into heat, which causes thermal expansion within acoustic pulse source 212. The thermal expansion of acoustic pulse source 212 generates acoustic pulse 226.

[0043] The kinetic energy of the ions in the ion beam 208 is controlled to adjust the depth 214 of the acoustic pulse source 212. The kinetic energy is controlled by adjusting the ion beam source 202 or by inserting an attenuator (not shown) between the ion beam source 202 and the structure 206.

[0044] Acoustic sensor 222 is located at the second surface 224 of structure 206. Acoustic sensor 222 is positioned to receive acoustic pulses originating from within structure 206. The acoustic pulses are generated by thermal expansion caused by the ion beam 208 of ion beam source 202. Connector 218 is located between the first surface 210 and the second surface 224. Acoustic pulse 226 is generated by acoustic pulse source 212. Acoustic sensor 222 senses the propagation time and magnitude of acoustic pulse 226 generated by acoustic pulse source 212. The sensing of the propagation time and magnitude of acoustic pulse 226 generated by acoustic pulse source 212 forms a response. As depicted, acoustic pulse 226 is represented by a plurality of arrows 228.

[0045] As depicted, some of the multiple arrows 228 are blocked by inconsistencies 230. This indicates the portion of the acoustic pulse 226 blocked by the inconsistencies 230. Because the inconsistencies 230 block the acoustic pulse 226, at least one of the magnitude or propagation time of the acoustic pulse 226 received at the acoustic sensor 222 is affected by the presence of the inconsistencies 230.

[0046] The non-conforming portion 230 in the joint 218 is a gap. The joint 218 is the connection portion between the first part 232 and the second part 234 of the structure 206 at the interface 236 of the first part 232 and the second part 234.

[0047] The connector inspection system 238 includes an ion beam source 202 and an acoustic sensor 222. The ion beam source 202 is oriented toward the acoustic sensor 222. The acoustic sensor 222 is positioned to receive acoustic pulses formed by the energy of the ion beam 208 originating from the ion beam source 202.

[0048] The connector inspection system 238 includes an ion beam source 202 oriented toward the structure 206 and an acoustic sensor 222. The acoustic sensor 222 is positioned to receive acoustic pulses originating from within the structure 206. The acoustic pulses, including acoustic pulse 226, are generated by thermal expansion caused by the ion beam 208 of the ion beam source 202.

[0049] Ion beam 208 is sent into structure 206 to enable non-destructive inspection of connector 218 of structure 206. Connector 218 is then subjected to non-destructive inspection by connector inspection system 238. As depicted, connector inspection system 238 includes ion beam source 202 and acoustic sensor 222. However, other components may be present in connector inspection system 238.

[0050] Figure 2 The illustration of the connector inspection system 238 is not intended to imply any physical or architectural limitations on the illustrative implementation. Other components besides those shown, or components that replace the shown components, may be used. Some components may be unnecessary.

[0051] For ease of illustration, ion beam source 202 is indicated by a box. However, ion beam source 202 can take any desired form. In some illustrative embodiments, ion beam source 202 is one of a cyclotron, a van der Graff generator, or a linear accelerator. Although ion beam source 202 is depicted as sending an ion beam 208 toward acoustic sensor 222, ion beam 208 is sent into structure 206 at any desired angle.

[0052] In some illustrative embodiments, an attenuator (not shown) is positioned between the ion beam source 202 and the structure 206. In some illustrative embodiments, a fixing device (not shown) holds the structure 206. In some illustrative embodiments, the fixing device places the structure 206 in a tensioned state.

[0053] Now go to Figure 3 According to an illustrative embodiment, an intensity graph depicting the response from a joint inspection is provided. Graph 300 includes responses 302 and 304. Response 302 is an acceptable response. Response 302 is generated by an acoustic pulse propagating through a structure having an acceptable level of inconsistency. Response 304 is generated by an acoustic pulse encountering an unacceptable level of inconsistency while propagating through the structure. In some illustrative embodiments, response 304 is generated by a received acoustic pulse 112. Figure 1The physical representation of the response 146.

[0054] Graph 300 has an x-axis 306 for time. Graph 300 also has a y-axis 308 for intensity. The x-axis 306 is a measure of propagation time, for example... Figure 1 The propagation time is 142. The Y-axis 308 is an indication of the magnitude, for example... Figure 1 The order of magnitude is 144.

[0055] Now go to Figure 4 The illustration shows a flowchart of a method for inspecting joints in a structure, based on an illustrative embodiment. It can be used... Figure 1 The connector inspection system 100 is used to perform method 400. It can be used... Figure 2 The ion beam source 202 and acoustic sensor 222 are used to perform method 400. In some illustrative embodiments, response 302 or response 304 is a physical representation of the response produced by method 400.

[0056] Method 400 sends an ion beam to a first surface of the structure using an ion beam source to form an acoustic pulse source in the structure at a depth corresponding to the Bragg peak of the ion beam, wherein the acoustic pulse source is adjacent to a connector (operation 402). Method 400 senses the propagation time and magnitude of the acoustic pulse generated by the acoustic pulse source using an acoustic sensor located on a second surface of the structure, thereby forming a response, wherein the connector is located between the acoustic pulse source and the second surface (operation 404). Method 400 then terminates.

[0057] In some illustrative embodiments, method 400 controls the kinetic energy of ions in the ion beam before sending the ion beam into the structure to adjust the depth of the acoustic pulse source (operation 406). In some illustrative embodiments, controlling the kinetic energy of the ions in the ion beam includes adjusting the ion beam source or inserting at least one of an attenuator between the ion beam source and the structure (operation 408). In some illustrative embodiments, the depth is between the first surface and the connector.

[0058] In some illustrative embodiments, method 400 mechanically places the structure in a tensioned state by associating the structure with a fixation device before sending an ion beam into the structure (operation 410). Placing the structure in a tensioned state allows for testing of the bonding strength.

[0059] Method 400 compares the response to an acceptable response (operation 412), and if the response has an magnitude exceeding the acceptable response, an inconsistency is identified (operation 414). In some illustrative embodiments, the magnitude of the response is significantly lower than the acceptable response. In these illustrative examples, an inconsistency is identified if the magnitude of the response is significantly lower than the acceptable response. If the inconsistency exceeds a tolerance, the inconsistency is identified.

[0060] In some illustrative embodiments, an acceptable response is selected such that a response of magnitude equal to or greater than the acceptable response is associated with a joint having an acceptable strength. A response having a magnitude equal to or greater than the acceptable response has an amount and size of inconsistency within tolerance limits. An acceptable response is selected such that a response of magnitude equal to or greater than the acceptable response is associated with a joint having an acceptable level of inconsistency.

[0061] In some illustrative embodiments, method 400 sends a second ion beam into a first surface of the structure using an ion beam source to form a second acoustic pulse source in the structure at a second depth corresponding to the Bragg peak of the second ion beam (operation 416). In these illustrative embodiments, method 400 senses the propagation time and magnitude of the acoustic pulse generated by the second acoustic pulse source using an acoustic sensor located on the second surface, thereby forming a second response (operation 418).

[0062] In some illustrative embodiments, method 400 controls the kinetic energy of the ions in the second ion beam to adjust a second depth of the acoustic pulse source before sending the second ion beam into the structure, such that the second depth differs from the first depth (operation 420). In some illustrative embodiments, controlling the kinetic energy of the ions in the second ion beam includes adjusting the ion beam source or inserting at least one of an attenuator between the ion beam source and the structure (operation 422).

[0063] Now go to Figure 5 The illustration depicts a flowchart of a method for inspecting joints in a structure, based on an illustrative embodiment. It can be used... Figure 1 The connector inspection system 100 is used to perform method 500. It can be used... Figure 2 The ion beam source 202 and acoustic sensor 222 are used to perform method 500. In some illustrative embodiments, response 302 or response 304 is a physical representation of the response produced by method 500.

[0064] Method 500 repeatedly delivers an ion beam to a first surface of the structure to form an acoustic pulse source within a first portion of the structure located on a first side of the joint (operation 502). Method 500 senses the propagation time and magnitude of the acoustic pulse generated by the acoustic pulse source at a second surface of a second portion of the structure, thereby forming a response, wherein the joint is the interface between the first and second portions of the structure (operation 504). Method 500 determines, based on the response, whether an inconsistency exists in the joint (operation 506). Method 500 then terminates.

[0065] In some illustrative embodiments, method 500 controls the kinetic energy of the ions in each ion beam before sending the respective ion beams into the structure to adjust the depth of the corresponding acoustic pulse source generated by the respective ion beams (operation 508). In some illustrative examples, the kinetic energy of the ions in each ion beam is controlled such that the ion beam has at least two distinct Bragg peaks (operation 510). With the aid of ion beams having at least two distinct Bragg peaks, the ions dissipate energy at at least two distinct depths within the structure. By dissipating energy at different depths, acoustic pulse sources are generated at different depths.

[0066] In some illustrative examples, determining the presence of inconsistencies in a joint involves comparing the magnitude of the response to the magnitude of an acceptable response (operation 512). An acceptable response magnitude is derived by examining structures with the same design and acceptable quality. The acceptable response magnitude is selected such that all responses reaching or exceeding the acceptable response magnitude are within tolerance.

[0067] As used herein, the phrase “at least one” when used with a series of items means that different combinations of one or more of the listed items may be used, and only one of each of the listed items may be required. For example, “at least one of item A, item B, or item C” may include, but is not limited to: item A; item A and item B; or item B. This embodiment may also include: item A, item B, and item C; or item B and item C. Of course, any combination of these items may exist. In other embodiments, “at least one” may be, for example, but not limited to: two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The item may be a specific object, thing, or category. In other words, any combination of items with at least one of any number of items may be used from the listed items, but not all items in the listed items are required.

[0068] As used in this article, “multiple” when referring to projects means one or more projects.

[0069] The flowcharts and block diagrams depicting different embodiments illustrate the architecture, functionality, and operation of some possible implementations of the apparatus and methods in the illustrative embodiments. In this regard, each block in the flowchart or block diagram may represent at least one of a module, segment, function, or operation or step.

[0070] In some alternative embodiments of the illustrative implementation, one or more functions marked in the boxes may occur in a different order than those shown in the figures. For example, in some cases, depending on the functions involved, two consecutively shown boxes may be performed substantially simultaneously, or sometimes these boxes may be performed in reverse order. Additionally, other boxes may be added besides those shown in the flowchart or block diagram. Some boxes may be optional. For example, some operations of 406 to 422 may be optional. As another embodiment, some operations of 508 to 512 may be optional.

[0071] It can be like Figure 6 The aircraft manufacturing and maintenance method 600 shown and such Figure 7 An illustrative embodiment of this disclosure is described within the context of the aircraft 700 shown. First, turn to... Figure 6 The illustration depicts a method for manufacturing and maintaining an aircraft according to an illustrative embodiment. In the early stages of production, the aircraft manufacturing and maintenance method 600 may include... Figure 7 Specifications and design of the aircraft 700 in China 602 and material procurement 604.

[0072] During the production process, the components and sub-assemblies of the aircraft 700 are manufactured 606 and the system is integrated 608. Afterward, the aircraft 700 can be inspected and delivered 610 for service entry 612. During the service period 612, performed by the customer, the aircraft 700 is scheduled for routine maintenance 614 (this may also include modification, refitting, refurbishment, or other maintenance).

[0073] The various processes of the aircraft manufacturing and maintenance method 600 can be performed or executed by a system integrator, a third party, and / or an operator. In these embodiments, the operator may be a customer. For the purposes of this description, the system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; the third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and the operator may be an airline, leasing company, military entity, service organization, etc.

[0074] Now for reference Figure 7 , Figure 7 An illustration depicts an aircraft capable of implementing an illustrative embodiment. In this embodiment, through... Figure 6 The aircraft manufacturing and maintenance method 600 produces an aircraft 700, and the aircraft 700 may include an airframe 702 having multiple systems 704 and an interior 706. Embodiments of system 704 include one or more of a propulsion system 708, an electrical system 710, a hydraulic system 712, and an environmental system 714. Any number of other systems may be included.

[0075] The equipment and methods implemented herein can be used in any one or more stages of aircraft manufacturing and maintenance method 600. Figure 6 One or more illustrative embodiments may be manufactured or used during at least one of the following: component and sub-assembly manufacturing 606, system integration 608, service entry 612, or maintenance and overhaul 614. For example, the joint inspection system 100 may be used to inspect the structure 106 during component and sub-assembly manufacturing 606. In some illustrative embodiments, the joint inspection system 100 is used to inspect the structure 106 during maintenance and overhaul 614. As an example, method 400 or method 500 may be used to inspect the joint 104 during component and sub-assembly manufacturing 606. The structure 106 may be a component of the aircraft 700, such as a component of the fuselage 702 or interior 706.

[0076] Illustrative embodiments provide a joint inspection system and a method for inspecting joints. In one illustrative embodiment, an ultrasonic source is positioned at a selected depth within a structure. A monoenergetic beam of ions (e.g., protons) travels through the material and dissipates most of its energy at a specific depth known as the Bragg peak. A stream of ions delivers a thermal spike to a small volume within the structure to be tested. The thermal pulse generates an acoustic pulse that propagates to the surface of the structure. Acoustic sensors on the surface evaluate the propagation time and magnitude of the acoustic pulse. The propagation time and magnitude of the acoustic pulse reveal inconsistencies such as voids or unbonded areas. In some illustrative embodiments, the structure is placed under structural tension before the ion beam is delivered into the structure.

[0077] Changing the ion energy allows for the generation of acoustic pulses at selected depths. This energy allows us to slide the acoustic pulse source from one side of the connector to the other, thereby enhancing sensitivity to any weak points.

[0078] The connector inspection system includes: an acoustic sensor for measuring acoustic signals within the structure; and an ion beam source, such as a cyclotron or van der Graff generator. The structure to be inspected is provided. In some illustrative embodiments, a fixture is provided to hold the structure within the ion beam. In some illustrative embodiments, the fixture may also hold an attenuator. In these illustrative embodiments, an attenuator is provided to control the energy of the ions entering the object.

[0079] To inspect the structure, it is placed in a fixture. The structure is oriented such that the desired portion of the structure is in the path of the ion beam. Acoustic sensors are placed on the surface of the structure. The kinetic energy of the ions is set. This kinetic energy is adjusted by regulating the ion beam source or by inserting an attenuator between the ion beam source and the structure. The ion beam source emits pulses of monoenergetic ions (e.g., protons). The ion pulses enter the structure and dissipate most of their energy at a specific depth known as the Bragg peak. Dissipating most of the energy at this specific depth generates a thermal spike within a small volume. This volume expands slightly but rapidly, thereby generating acoustic pulses that propagate to the surface of the structure. At least one acoustic sensor on the surface records the propagation time and magnitude of the acoustic pulses.

[0080] At least one of the operators or the computer compares the sound propagation time and / or magnitude to a reference value. The reference value includes at least one of acceptable or unacceptable values. If a pulse from inside the structure arrives later and / or weaker than a pulse from the same type of structure with the desired quality, it indicates the presence of an undesirable inconsistency (e.g., a void or unbonded area). If a pulse from inside the structure arrives later and / or weaker than a pulse from the structure with an acceptable inconsistency, it indicates an excess of tolerance inconsistency.

[0081] Changing the energy of the ions in the ion beam allows for the generation of acoustic pulses at a selected depth. Compared to X-ray inspection, the illustrative embodiment allows for the inspection of thicker structures. By employing a chirping technique—sending ion beams of varying kinetic energies to the same location—the joint inspection system provides superior depth resolution compared to conventional inspections.

[0082] The illustrative embodiments provide superior resolution and sensitivity compared to conventional ultrasound examinations. While the illustrative embodiments use ultrasound, the connector inspection system in these embodiments provides superior resolution and sensitivity with fewer transducers because it generates ultrasound pulses near the area to be inspected within the structure.

[0083] The relationship between energy dissipation and depth is specific to ions in an ion beam. Energy dissipation exhibits a spike. This narrow range of dissipation across depth offers advantages.

[0084] In the illustrative embodiment, no acoustic transducer generates a pulse. Instead, an ion pulse enters the object. The ions dissipate some energy in the initial portion of their path, but most of it is dissipated within a narrow depth range at the Bragg peak. This energy dissipation at the Bragg peak generates an acoustic pulse source within the object. Acoustic energy propagates from the ion beam (pulse) source along a direct path. If an inconsistency exists, most of the direct path will quickly encounter that inconsistency.

[0085] Compared to conventional ultrasound inspection, a greater portion of the acoustic energy is dispersed by inconsistencies. Compared to conventional ultrasound inspection, the acoustic sensor measurements of the joint inspection system show a greater difference in response between structures with and without inconsistencies exceeding the tolerance limit. The physical characteristics of the inspection process provide higher sensitivity to inconsistencies compared to conventional ultrasound inspection.

[0086] Various illustrative embodiments have been described for purposes of explanation and description, and this description is not intended to be exhaustive or limited to the embodiments disclosed. Many variations and modifications will be apparent to those skilled in the art. Furthermore, different illustrative embodiments may provide different features compared to other illustrative embodiments. The selection and description of one or more chosen embodiments are intended to best explain the principles of the embodiments, their practical application, and to enable others skilled in the art to understand the disclosure of various embodiments with various variations suitable for the contemplated particular purpose.

Claims

1. A method for inspecting joints in a structure, the method comprising: An ion beam is sent from an ion beam source to a first surface of the structure to form an acoustic pulse source in the structure at a depth corresponding to the Bragg peak of the ion beam, wherein the acoustic pulse source is adjacent to the connector; A response is generated by sensing the propagation time and intensity magnitude of an acoustic pulse generated by the acoustic pulse source using an acoustic sensor located on the second surface of the structure, wherein the connector is located between the acoustic pulse source and the second surface; and Inconsistencies in the joint are identified by recognizing at least one of the propagation time or the intensity magnitude as exceeding an acceptable response.

2. The method according to claim 1, further comprising: Before the ion beam is sent into the structure, the kinetic energy of the ions in the ion beam is controlled to adjust the depth of the acoustic pulse source.

3. The method according to claim 2, wherein, Controlling the kinetic energy of ions in the ion beam includes at least one of the following: adjusting the ion beam source, or inserting an attenuator between the ion beam source and the structure.

4. The method according to claim 1, further comprising: Before the ion beam is sent into the structure, the structure is mechanically placed in a tensioned state by associating the structure with a fixing device.

5. The method according to claim 1, further comprising: Compare the response with an acceptable response; and If the magnitude of the response exceeds the acceptable level, an inconsistency is identified.

6. The method according to claim 1, further comprising: The second ion beam is sent from the ion beam source to the first surface of the structure to form a second acoustic pulse source in the structure at a second depth corresponding to the Bragg peak of the second ion beam; and The acoustic sensor located on the second surface senses the propagation time and intensity magnitude of the acoustic pulse generated by the second acoustic pulse source, thereby forming a second response.

7. The method according to claim 6, further comprising: Before the second ion beam is sent into the structure, the kinetic energy of the ions in the second ion beam is controlled to adjust the second depth of the acoustic pulse source, such that the second depth is different from the stated depth.

8. The method according to claim 7, wherein, The kinetic energy of the ions controlling the second ion beam includes at least one of the following: adjusting the ion beam source, or inserting an attenuator between the ion beam source and the structure.

9. The method according to claim 1, wherein, The depth is located between the first surface and the connector.

10. A joint inspection system for performing the method of inspecting a joint in a structure according to claim 1, the joint inspection system comprising: Acoustic sensor; as well as An ion beam source, oriented toward the acoustic sensor; The ion beam source is configured to send an ion beam into a first surface of the structure to form an acoustic pulse source in the structure at a depth corresponding to the Bragg peak of the ion beam, wherein the acoustic pulse source is adjacent to the connector; and The acoustic sensor is configured to sense the propagation time and intensity magnitude of an acoustic pulse generated by the acoustic pulse source at a second surface of the structure, thereby generating a response. The connector is located between the acoustic pulse source and the second surface. The joint inspection system further includes a processor configured to identify inconsistencies in the joint based on at least one of the propagation time or intensity magnitude of the acoustic pulse exceeding an acceptable response.

11. The joint inspection system according to claim 10, further comprising: A beam steering system configured to change the shape of the ion beam generated by the ion beam source.

12. The joint inspection system according to claim 10, wherein, The ion beam source is one of a cyclotron, a van der Graff generator, or a linear accelerator.

13. The joint inspection system according to claim 10, further comprising: An attenuator located between the ion beam source and the target of the ion beam source.

14. The joint inspection system according to claim 10, further comprising: A fixing device configured to hold the structure to be inspected in the path of the ion beam source and to make the structure to be inspected into acoustic contact with the acoustic sensor.

15. The connector inspection system according to claim 14, wherein, The fixing device is configured to place the structure to be inspected in a tensioned state.

16. A method for inspecting joints in a structure, the method comprising: An ion beam is repeatedly sent to a first surface of the structure to form an acoustic pulse source within a first portion of the structure located on a first side of the connector, such that each of the acoustic pulse sources is formed at a depth corresponding to the Bragg peak of an ion beam in the ion beam. The propagation time and intensity magnitude of an acoustic pulse generated by the acoustic pulse source are sensed at the second surface of the second part of the structure to form a response, wherein the connector is the interface between the first part and the second part of the structure; and The inconsistency in the joint is determined by identifying that at least one of the propagation time or the intensity magnitude of each acoustic pulse in the response exceeds an acceptable response.

17. The method of claim 16, further comprising: Before each corresponding ion beam is sent into the structure, the kinetic energy of the ions in each ion beam is controlled to adjust the depth of the corresponding acoustic pulse source generated by the corresponding ion beam.

18. The method according to claim 17, wherein, The kinetic energy of the ions in each ion beam is controlled such that the ion beam has at least two distinct Bragg peaks.

19. The method of claim 16, wherein, Determining whether there is an inconsistency in the joint includes comparing the magnitude of the intensity of the response with the magnitude of an acceptable response.

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