Component Imaging System, Device, and Method

Abstract

A system for imaging a component that defines a negative space is provided, including a component imaging assembly, a bolus insert, and an imaging device. The bolus insert is capable of being positioned within the negative space of the component when the component is positioned within the imaging field of the imaging device to produce an image of the component. A method is provided that includes positioning the bolus insert within the negative space of the component and scanning the component with the bolus insert to create an image of the component. A component imaging assembly is provided that includes a component, the component including a first portion having a first thickness that is greater than a second thickness of a second portion; and a bolus insert positioned adjacent to the second portion, the bolus insert having a bolus thickness that is substantially similar to a difference between the first thickness and the second thickness. The bolus insert has a bolus material density that is within fifteen percent (15%) of the component material density.

Description

Technical Field

[0001] This subject matter generally relates to imaging components, and more particularly, to internal imaging of components using image scanning. Background Art

[0002] Internal imaging or radiographic testing of components (e.g., gas turbine engine components such as airfoils, shrouds, etc.) results in scanning of their image data representative of the relative density of the material. Variations in the material density shown in the component scan can help identify defects, measure internal channels or cavities, etc. Certain geometric features of the component may cause artifacts in the image data, making it appear that there are different densities in the component when there actually are not, which may lead to falsely concluding that the component contains one or more defects or may inaccurately indicate the size and / or location of internal component features. For radiographic imaging, artifacts may be caused by scatter within the X-ray beam, beam hardening, and / or partial volume effects and their interaction with the component. Accordingly, improved imaging devices and methods for reducing the impact of image artifacts will be needed. Summary of the Invention

[0003] Aspects and advantages of the present disclosure will be set forth in part in the following description, or may be obvious from the description, or may be learned by practice of the subject matter of the present disclosure.

[0004] In one embodiment of the subject matter, a system for imaging a component is provided. The component defines a negative space, and the system includes a component imaging assembly; a bolus insert; and an imaging device. The bolus insert is capable of being positioned within the negative space of the component when the component is positioned within the imaging field of the imaging device to produce an image of the component.

[0005] In another embodiment of the subject matter, a method is provided. The method includes positioning a bolus insert within the negative space defined by a component, and scanning the component with the bolus insert to produce an image of the component.

[0006] In another embodiment of the subject matter, a component imaging assembly is provided. The component imaging assembly includes a component that includes a first portion having a first thickness and a second portion having a second thickness. The first thickness is greater than the second thickness. The component imaging assembly further includes a bolus insert positioned adjacent to the second portion. The bolus insert has a bolus thickness that is substantially similar to the difference between the first thickness and the second thickness. The bolus material density of the bolus insert is within fifteen percent (15%) of the component material density of the component.

[0007] These and other features, aspects, and advantages of the present disclosure will be better understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the presently disclosed subject matter and, together with the description, serve to explain the principles of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A complete and enabling disclosure of the present disclosure, including the best mode thereof, for the ordinary skill in the art, is set forth in the specification, which makes reference to the accompanying drawings, in which:

[0009] Figure 1 A schematic cross-sectional view of a gas turbine engine in accordance with various embodiments of the present subject matter is provided.

[0010] Figure 2 A schematic diagram of a system including components (such as Figure 1 components of a gas turbine engine) and a component imaging assembly in accordance with an embodiment of the present subject matter is provided.

[0011] Figure 3 An image of a component taken without a bolus insert is provided.

[0012] Figure 4 An image of a component taken with a bolus insert in accordance with an embodiment of the present subject matter is provided.

[0013] Figure 5 A flowchart illustrating a method for generating an image of a component in accordance with an embodiment of the present subject matter is provided. DETAILED DESCRIPTION

[0014] Reference will now be made in detail to the present embodiments of the disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Identical or similar designations in the drawings and description have been used to refer to the same or similar parts of the disclosure.

[0015] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to denote the position or importance of the individual components.

[0016] The terms “front” and “rear” refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, front refers to a position closer to the engine inlet, and rear refers to a position closer to the engine nozzle or exhaust.

[0017] The terms “upstream” and “downstream” refer to the relative direction with respect to the flow of fluid in a fluid path. For example, “upstream” refers to the direction from which the fluid flows out, and “downstream” refers to the direction to which the fluid flows.

[0018] The terms “coupled,” “fixed,” “attached,” etc. refer to direct coupling, fixing, or attachment, as well as indirect coupling, fixing, or attachment through one or more intermediate components or features, unless otherwise specified herein.

[0019] Unless the context clearly dictates otherwise, the singular forms “a,” “an,” and “the” include plural referents.

[0020] Throughout the specification and claims, approximating language is applied to modify any quantitative representation that can vary without resulting in a change in the basic function associated therewith. Accordingly, values modified by one or more terms, such as “about,” “approximately,” and “substantially,” are not limited to the specified exact value. In at least some instances, the approximating language can correspond to the precision of the instrument for measuring the value, or the precision of the method or machine for constructing or manufacturing the components and / or systems. The approximating language can refer to being within a margin of + / −1, 2, 4, 10, 15, or 20% of a single value, a range of values, and / or the endpoints defining a range of values.

[0021] Herein and throughout the specification and claims, range limitations are combined and interchanged, and these ranges are identified and include all subranges subsumed therein, unless the context or language indicates otherwise. For example, all ranges disclosed herein include the endpoints, and the endpoints can be combined independently of one another.

[0022] Generally, the present subject matter provides systems and methods for improving component imaging. For example, a system as described herein includes a component imaging assembly that includes a component defining a negative space and a bolus insert positioned within the negative space. The system further includes an imaging device, and the component is positioned within the imaging field of the imaging device to generate an image of the component. The shape of the bolus insert can at least partially complement the negative space to standardize or homogenize the component geometry and can have a density close to that of the component, helping to reduce or eliminate image artifacts caused by scatter, beam hardening, and / or partial volume effects, e.g., by standardizing the distance of the beam path for all views or all captured projections. Additionally, the systems and methods described herein can generate image data having a consistent signal-to-noise ratio, contrast, and resolution despite irregular component geometry.

[0023] Referring now to the drawings, like numerals in all the figures represent like elements, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an embodiment of the present disclosure. For Figure 1 an embodiment, the gas turbine engine is a high bypass turbofan jet engine, referred to herein as “turbofan engine 10.” As Figure 1As shown, the turbofan engine 10 defines an axial direction A (extending parallel to a provided longitudinal centerline 12 as a reference) and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a core turbomachine 16 disposed downstream of the fan section 14.

[0024] The illustrated core turbomachine 16 generally includes a substantially tubular outer casing 18 that defines an annular inlet 20. The outer casing 18 surrounds, in serial flow relationship, a compressor section that includes a booster or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustor section 26; a turbine section that includes a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0025] For the depicted embodiment, the fan section 14 includes a fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced-apart manner. As shown, the fan blades 40 generally extend radially outward from the disk 42 in the radial direction R. The fan blades 40 and the disk 42 are rotatable together about a longitudinal axis (illustrated as longitudinal centerline 12) by the LP shaft or spool 36. In some embodiments, a power gearbox having a plurality of gears may be included for reducing the rotational speed of the LP shaft or spool 36 to a more efficient fan rotational speed.

[0026] Still referring to Figure 1 the embodiment, the disk 42 is covered by a rotatable front nacelle 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. Additionally, the fan section 14 includes an annular fan housing or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the core turbomachine 16. It should be understood that the nacelle 50 may be configured to be supported relative to the core turbomachine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Additionally, a downstream section 54 of the nacelle 50 may extend over the exterior of the core turbomachine 16 to define a bypass airflow passage 56 therebetween.

[0027] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through the nacelle 50 and / or the associated inlet 60 of the fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of the air 58, indicated by arrow 62, is directed or routed into the bypass air flow path 56, and a second portion of the air 58, indicated by arrow 64, is directed or routed into the LP compressor 22. The ratio between the first portion 62 of the air and the second portion 64 of the air is commonly referred to as the bypass ratio. When the second portion 64 of the air is routed through the high pressure (HP) compressor 24 and into the combustion section 26, its pressure is then increased, where it is mixed with fuel and burned to provide combustion gases 66.

[0028] The combustion gases 66 are routed through the HP turbine 28, where a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via successive stages of HP turbine stator vanes 68 coupled to the outer casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 and thus supporting the operation of the HP compressor 24. The combustion gases 66 are then routed through the LP turbine 30, where a second portion of the thermal and kinetic energy is extracted from the combustion gases 66 via successive stages of LP turbine stator vanes 72 coupled to the outer casing 18 and LP turbine rotor blades 74 coupled to the LP shaft or spool 36, thereby rotating the LP shaft or spool 36 and thus supporting the operation of the LP compressor 22 and / or the rotation of the fan 38.

[0029] The combustion gases 66 are then routed through the jet exhaust nozzle section 32 of the core turbofan engine 16 to provide propulsive thrust. At the same time, as the first portion 62 of the air is routed through the bypass air flow path 56 before it exits from the fan nozzle exhaust section 76 of the turbofan engine 10, the pressure of the first portion 62 of the air is significantly increased, also providing propulsive thrust. The HP turbine 28, the LP turbine 30, and the jet exhaust nozzle section 32 at least partially define a hot gas path 78 for routing the combustion gases 66 through the core turbofan engine 16.

[0030] Reference Figure 2, shows a system 100 according to various embodiments of the present subject matter. As described herein, the system 100 is used to image components 102 (e.g., components of a turbofan engine 10 such as fan blades 40, turbine stator vanes 68, 72, turbine rotor blades 70, 74, turbine shrouds, etc.). The system includes a component imaging assembly 104 that is used to image the component 102 using a push injection insert 106. More specifically, the component 102 defines a negative space 108, such as a groove, lip, flange, channel, etc., such that at least a portion of the component 102 is thinner than another portion of the component 102. That is, a first portion 110 has a first thickness t1 ( Figure 3 , 4 ) and a second portion 112 has a different second thickness t2 ( Figure 3 , 4 ), where the first thickness t1 is greater than the second thickness t2 or the second thickness t2 is less than the first thickness t1. The push injection insert 106 is positioned in the negative space 108 to increase the thickness of the second portion 112 such that the component imaging assembly 104 has a substantially uniform thickness in cross-section. In at least some embodiments, the push injection insert 106 has a push injection thickness t b ( Figure 4 ) that is substantially similar to the difference between the second thickness t2 and the first thickness t1 such that the push injection insert 106 substantially fills the negative space 108, increasing the thickness of the second portion 112 to be substantially equal to the thickness of the first portion 110.

[0031] Although Figures 2 to 4 depicts a component 102 having only two component thicknesses t1 and t2 that define a negative space 108, it should be understood that the present disclosure is also applicable to components 102 having a negative space 108 defined by more than two thicknesses. For example, the negative space 108 can be defined by a curved surface, etc., where the thickness of the component 102 varies from one point to another along a certain length such that both the component 102 and the push injection insert 106 positioned adjacent to the surface of the component have multiple thicknesses. However, it should be understood that for any two of the multiple component thicknesses that are positioned adjacent to the push injection insert 106, the push injection insert 106 has a thickness t b that can be substantially similar to the difference between the two component thicknesses t1, t2 such that the push injection insert 106 substantially fills the negative space 108 defined by the component surface between those points along the component surface having the first thickness t1 and the second thickness t2.

[0032] System 100 also includes an imaging device 114. For example, the imaging device 114 is a radiographic imaging device, such as a digital radiography (DR) machine, a film radiography camera, a computed tomography (CT) scanner, etc. In some embodiments, the radiographic imaging device 114 includes a radiographic source 116 and a radiographic receiver 118, such as a detector or film. Component 102 is located within the imaging field 120 of the imaging device 114 to generate an image 122 of the component 102( Figure 3 , 4 ). The image 122 depicts the interior of the component 102, which can assist in making measurements at or near internal features (such as internal channels, cavities, etc.), and / or can assist in identifying defects (such as cracks, fissures, inadvertent holes or openings) in the component material, and / or other types of weaknesses in the component material.

[0033] The bolus insert 106 disposed in the negative space 108 helps to reduce or eliminate image artifacts that may erroneously indicate the presence of openings, cracks, gaps, holes, etc. in the material forming the component 102. More specifically, certain geometric features of the component 102, such as the flange 124 defined around the edge of the annular component 102 shown in Figure 2 , may cause artifacts in the image data, making it appear that there are different densities in the component 102 (these density differences typically indicate openings, cracks, etc. in the component 102, such as defects), but in fact there are no different densities. The flange 124 defines the negative space 108, and the bolus insert 106 positioned in the negative space 108 reduces or eliminates the effect of the negative space 108 by "uniformizing" the component geometry or increasing the thickness of the component 102 in the region of the flange 124, such that the component 102 appears to have a uniform geometry and thickness to the imaging device 114. The uniformity of the component geometry and thickness thus reduces image artifacts, which can be understood as a decrease or variation in the signal from the imaging device (e.g., a decrease in the CT signal in the case where the imaging device 114 is a CT scanner), which may be confused with openings, gaps, cracks, etc. in the component material.

[0034] Accordingly, the bolus insert 106 has a shape or geometry that is at least partially complementary to the negative space 108, and a density approximating that of the component 102. The negative space 108 has a geometry that can be referred to as a spatial geometry, which is defined by the component 102. The bolus insert 106 has a bolus geometry that is at least partially complementary to the spatial geometry. In at least some embodiments, the bolus geometry of the bolus insert 106 is such that the bolus insert 106 fits tightly onto the component 102 within the negative space 108, e.g., in a position closely approximating where there is no negative space 108 in the component material. For example, as Figure 2As shown, the flange 124 of the component 102 can be annular or ring-shaped such that the negative space 108 is annular or ring-shaped. In such an embodiment, the bolus insert 106 has a complementary annular or ring shape such that the bolus insert 106 fills the negative space 108, e.g., such that for the imaging device 114, the negative space 108 appears non-existent. The size and shape of the bolus insert 106 can reduce or eliminate the gap between the bolus insert 106 and the component 102. Thus, for the depicted embodiment, the shape and size of the bolus insert 106 are designed to minimize or eliminate the negative space 108 defined by the flange 124. It should be understood that the bolus insert 106 can be shaped to conform to a particular negative space 108 and thus, one or more bolus inserts 106 can be manufactured for a single component 102 and / or multiple bolus inserts 106 can be manufactured for multiple components 102, e.g., having corresponding bolus inserts 106 that match the geometry of the respective negative spaces 108. Further, it should be understood that the bolus insert 106 need not be shaped only with respect to the component 102 and the negative space 108. For example, the bolus insert 106 can be shaped to complement the beam path, e.g., the beam path from the radiographic source 116 to optimize the beam path through the component 102.

[0035] Further, the component 102 is formed from a component material having a component material density. Similarly, the bolus insert 106 is formed from a bolus material having a bolus material density. To maximize the benefits of the bolus insert 106, the bolus material density should be as close as possible to the component material density, i.e., the bolus material should be within the density tolerance of the component material. For example, in some embodiments, the bolus material density is within fifteen (15%) of the component material density, i.e., the bolus material density is ±15% of the component material density. More particularly, the bolus material density is within ten (10%) of the component material density, i.e., the bolus material density is ±10% of the component material density. Even further, the bolus material density is within five (5%) of the component material density, i.e., the bolus material density is ±5% of the component material density. Having a bolus density that is substantially close to or equal to the component density helps to equalize the path length (e.g., for DR imaging) or projection (for CT imaging) to improve image quality, e.g., by reducing image artifacts. It should be understood that similar to the geometry of the bolus insert 106, the bolus material and the bolus material density can be matched to a particular component 102 and its component material density such that the bolus material density can vary between bolus inserts 106, e.g., if the component material and its component material density vary between components 102 using the bolus insert 106.

[0036] As Figure 2 shown, the component 102 is angled relative to the radiographic source 116 and the radiographic receiver 118 (e.g., a detector or film). In Figure 2In an embodiment, the component 102 is angled upward relative to the radiographic source 116 such that the proximal end 126 of the component 102 closest to the radiographic source 116 is at a raised height compared to the distal end 128 of the component 102 closest to the radiographic receiver 118. In other embodiments, the component 102 may be angled downward or otherwise relative to the radiographic source 116. The illustrated component 102 is angled at an angle α relative to the horizontal direction H, i.e., the angle α is measured from the horizontal direction H to the surface 130 of the component 102 facing the horizontal direction H. It should be understood that the horizontal direction H is orthogonal to the vertical direction V.

[0037] The angle α of the component 102 relative to the radiographic source 116 and / or the radiographic receiver 118 can be optimized based on, for example, the configuration or design of the bolus insert 106 to ensure optimal image quality. More specifically, given the configuration of the bolus insert 106, the angle α of the component 102 can be selected to minimize image noise as well as scatter, beam hardening, and / or partial volume effects, which may be caused by the interaction between the beam from the radiographic source 116 and the component 102. In some embodiments, the angle α can range from about 0° to about 90° relative to the horizontal direction H. As described herein, the bolus insert 106 has a shape that thickens the thinner regions of the component 102 to remove the spatial non-stationarity of the relevant image metrics, taking into account the angle α of the component 102 with the bolus insert 106 relative to the radiographic source 116 and the radiographic receiver 118 of the scanner or imaging device 114.

[0038] In addition, the component 102 can rotate about an axis A extending along the vertical direction V, as shown by the arrow 132 indicating the direction of rotation, to change the position of the component 102 for successive images. That is, the position of the component 102 can be changed between the images captured by the imaging device 114 such that, for example, the proximal end 126 of the component 102 is different from one position to another, and different portions of the component 102 are located at different positions relative to the radiographic source 116. The component 102 can be rotated to produce a complete 360° image of the component 102. In addition, it should be understood that the component 102 can be rotated manually or automatically. For example, the component 102 can be supported such that one or more operators manually reposition the component 102 between image captures, or the component 102 can be supported such that an automated machine repositions the component 102 between image captures. As described herein, the bolus insert 106 can extend throughout the negative space 108 or can extend only within a portion of the negative space 108. In embodiments where the bolus insert 106 extends only within a portion of the negative space 108, the bolus insert 106 can be repositioned as the component 102 is repositioned or rotated such that the bolus insert 106 is always located within the negative space 108 at or near the proximal end 126 of the component 102 to help reduce or eliminate data artifacts that may be caused by the negative space 108.

[0039] As previously described, in some embodiments, for example Figure 2 in the embodiment shown, the component 102 is annular or ring-shaped and is formed of a component material. For example, the component 102 can be an annular shroud of a turbofan engine 10 formed of a ceramic matrix composite (CMC) material. In various embodiments, the CMC material can include silicon carbide (SiC), silicon, silica, carbon, or an alumina matrix material and combinations thereof. Ceramic fibers can be embedded in the matrix, such as oxidation-stable reinforcing fibers, including monofilaments such as sapphire and silicon carbide (e.g., SCS-6 from Textron), and rovings and yarns including silicon carbide (e.g., from Ube Industries and from Dow Corning), aluminosilicates (e.g., Nextel 440 and 480 from 3M), and chopped whiskers and fibers (e.g., Nextel 440 and ), and optionally ceramic particles (e.g., oxides of Si, Al, Zr, Y and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite). For example, in certain embodiments, a fiber bundle including a ceramic refractory coating is formed into a reinforcement tape, such as a unidirectional reinforcement tape. Multiple tapes can be laid together (e.g., as a layer) to form a preform component. The fiber bundle can be impregnated with a slurry composition before or after forming the preform. The preform can then be heat treated, such as cured or burned out, to produce a high carbon residue in the preform, and subsequently chemically treated, such as infiltrated with a silicon melt, to obtain a component having a desired chemical composition formed of CMC material. In other embodiments, the CMC material can be formed as, for example, a carbon fiber cloth rather than a tape.

[0040] As previously described, the shape of the syringe insert 106 is complementary to the negative space 108 defined by the component 102. In Figure 2 the illustrated embodiment, the negative space 108 is annular and extends around the radially outer edge 134 of the component 102. Thus, in some embodiments, the syringe insert 106 can be a ring of syringe material that extends around the entire radially outer edge 134, i.e., around the circumference of the component 102 commensurate with the Figure 2 illustrated negative space 108. In other embodiments, the syringe insert 106 can be an arc of syringe material, i.e., a partial ring of syringe material, that extends around a portion of the radially outer edge 134 of the component 102 as Figure 2 illustrated, such that the syringe insert 106 does not fill all of the negative space 108 (is not commensurate with the negative space 108). More specifically, the arcuate syringe insert 106 extends over an arc having a certain angular length such that the arc extends over a range less than the entire 360° of the annular negative space 108.

[0041] Further, as previously described, the syringe insert 106 is formed of a syringe material having a density similar to the component material forming the component 102. In embodiments where the component material is a CMC material, the syringe material can be, for example, aluminum, which has a density close to or equal to the density of a typical CMC material. Thus, in at least some Figure 2 illustrated embodiments, the syringe insert 106 can be an arcuate insert formed of aluminum. As further illustrated in the Figure 2 embodiment of, when positioned between the radiographic source 116 and the radiographic receiver 118, the proximal end 126 of the component 102 is at an angle α of about 30° with respect to the horizontal direction H, and the arcuate syringe insert 106 is positioned on the proximal end 126. Additionally, as previously described, the component 102 can be repositioned between image captures, and as the component 102 rotates about the vertical direction V, the arcuate syringe insert 106 moves such that the syringe insert 106 is always positioned at the proximal end 126 of the component 102.

[0042] Now refer to Figure 3 and Figure 4 , by comparing two images 122 of the CMC annular shroud taken using CT imaging, the effect of the aluminum syringe insert 106 when imaging the CMC annular shroud component 102 as described herein can be determined. Figure 3 An image 122 of the CMC annular shroud component 102 without the syringe insert 106 is provided, while Figure 4 an image 122 of the CMC annular shroud component 102 with the syringe insert 106 is provided. Specifically comparing the regions indicated by the arrow 136 in each image, it should be understood that the CT image captured with the syringe insert 106 significantly reduces the image artifacts in the region of the flange 124 that defines the negative space 108. That is, in the region of the negative space 108, the thickness of the component 102 (i.e., the thickness of the flange 124) is less than the thickness of the rest of the component 102, and image artifacts appear in Figure 3 the image of (without the syringe insert 106), but are almost non-existent in Figure 4 the image of (with the syringe insert 106). Thus, it can be seen that the syringe insert 106 helps to reduce and in some cases can completely remove the image artifacts caused by scatter, beam hardening, and / or partial volume effects. As previously described, the reduction of image artifacts can improve component inspection for detection and / or metrology, for example, by preventing the misidentification of component defects, improving the measurement of component features, etc.

[0043] It should be understood that the annular shroud component 102 formed of CMC material and the arcuate syringe insert 106 formed of aluminum are provided only as examples. That is, the component 102 can be any component, device, or object formed substantially of any material and having a negative space 108 that is not limited to being annular. As some examples, the component 102 can be a metal compressor or turbine blade of a turbofan engine 10, or the component 102 can be a non-metallic object that is not part of a gas turbine engine, not used with a gas turbine engine, or not otherwise related to a gas turbine engine, such as, by way of example only, the component 102 can be an automotive component, a component of a household appliance, a medical device or implant, etc. As described herein, the syringe insert 106 has a geometry that is at least partially complementary to the negative space of the component 102 and is thus not limited to being arcuate or annular. In addition, the syringe insert 106 has a density that is substantially similar to the density of the component 102 and can thus be any suitable material having a substantially similar density (e.g., a metallic material, a non-metallic material, etc.). Of course, factors such as cost, availability, machinability, etc. can also be considered when selecting the syringe material, as long as the density of the selected syringe material is substantially similar to the density of the component material.

[0044] Turning now to Figure 5 , a flowchart of a method according to an embodiment of the present disclosure is provided. The depicted method 500 includes selecting (502) a bolus material for the bolus insert 106 that is positioned within the component 102 formed of the component material. The bolus material has a bolus density within the density tolerance of the component material, such as within about 5%, 10%, or 15% of the component material density, such that the bolus density is substantially close to or equal to the component density. The method 500 also includes shaping (504) the bolus insert 106 to conform to the negative space 108 defined by the component 102. As described herein, shaping the bolus insert 106 can include forming, machining, or otherwise shaping the bolus material to have a shape complementary to the shape of the negative space 108. The method 500 also includes positioning (506) the bolus insert 106 within the negative space 108 of the component 102 and setting (508) the component 102 having the bolus insert 106 between the radiographic source 116 and the radiographic receiver 118. As described herein, the imaging device 114 including the radiographic source 116 and the radiographic receiver 118 can be a digital radiography (DR) device, a film radiography device, a computed tomography (CT) device, etc., and as described herein, the component 102 having the bolus insert 106 can be angled relative to the radiographic source 116 and the radiographic receiver 118.

[0045] Still referring to Figure 5 , the method 500 also includes scanning (510) the component 102 having the bolus insert 106 to generate an image of the component 102. Figure 4 An example of such an image is provided in

[0046] Accordingly, as described herein, the subject matter provides a system and technique to reduce the impact of image artifacts in component imaging or component scanning. More specifically, a bolus or bolus insert is used to homogenize and reduce the impact of component geometry or thickness variations. Bolus inserts can be provided for a variety of components formed from any material having an irregular geometry. Because the bolus insert is manufactured to have the same or similar density as the component, the interaction of the imaging source (e.g., x-ray) with both the bolus insert and the component is similar. More importantly, because the bolus insert is manufactured to conform to the surface of the component and the thickness of the bolus insert is optimized such that, for example, the x-ray path length through the combination of the component and the bolus is standardized, artifacts due to the geometry of the component are reduced. Additionally, other spatially non-stationary image quality metrics (e.g., contrast, noise, and resolution in thick regions) are also standardized compared to thin regions of the component, resulting in more intuitive radiographic data. Thus, the component data acquired can be more easily evaluated by a human operator or computer-aided evaluation software.

[0047] The use of bolus inserts can improve inspections for defect detection or metrology, which can (e.g., through accurate identification of component defects) lead to improved component quality. As described herein, bolus inserts for component imaging can improve the evaluation of images, require less interrogation and judgment from an operator evaluating the images, and improve the repeatability and reproducibility of gauges. Additionally, bolus inserts in a component can improve scan times because the component does not require additional scans to mitigate image artifacts. Thus, bolus inserts can improve cycle times and inspection costs. Additionally, the use of bolus inserts for a component in component imaging can improve porosity detection and / or discrete indication detection. Additionally or alternatively, bolus inserts enable advanced diagnostic radiology as well as CT / DR internal metrology.

[0048] Accordingly, by placing an optimally manufactured bolus insert on a component, the interaction of the imaging source (e.g., x-ray beam) with the irregular geometry of the component can be optimized and the impact of image artifacts can be removed, enabling improved inspections for component defect detection, measurement, and evaluation. More specifically, with the bolus insert on the component, a consistent signal is captured on the imaging receiver or detector (e.g., x-ray detector). The consistent signal results in image data that is closer to the relative density of the component material being imaged. Image artifacts caused by scatter, beam hardening, and / or partial volume effects can be reduced or eliminated using this technique. Additionally, this technique can generate image data with a consistent signal-to-noise ratio, contrast, and resolution within an irregular component geometry where these issues would otherwise occur and make interpretation of the data difficult. Other advantages of the subject matter described herein can also be realized by those of ordinary skill in the art.

[0049] A further aspect of the present invention is provided by the subject matter of the following clauses:

[0050] 1. A system for imaging a component that defines a negative space, the system comprising: a component imaging assembly; a bolus insert; and an imaging device, wherein the bolus insert is capable of being positioned within the negative space of the component when the component is positioned within the imaging field of the imaging device to produce an image of the component.

[0051] 2. The system according to any preceding clause, wherein the negative space has a spatial geometry and wherein the bolus insert has a bolus geometry that is at least partially complementary to the spatial geometry.

[0052] 3. The system according to any preceding clause, wherein the component is formed of a component material having a component material density, wherein the bolus insert is formed of a bolus material having a bolus material density, and wherein the bolus material density is within fifteen percent (15%) of the component material density.

[0053] 4. The system according to any preceding clause, wherein the bolus material density is within ten percent (10%) of the component material density.

[0054] 5. The system according to any preceding clause, wherein the imaging device is a radiographic imaging device.

[0055] 6. The system according to any preceding clause, wherein the radiographic imaging device includes a radiographic source and a radiographic receiver.

[0056] 7. The system according to any preceding clause, wherein the component is angled relative to the radiographic source.

[0057] 8. The system according to any preceding clause, wherein the component is positioned at an angle α relative to a horizontal direction orthogonal to the vertical direction.

[0058] 9. The system according to any preceding clause, wherein the component is capable of rotating about an axis extending along the vertical direction to reposition the component within the imaging field.

[0059] 10. The system according to any preceding clause, wherein the component has a first thickness in a first portion and a second thickness in a second portion adjacent to the negative space, the second thickness being less than the first thickness, and wherein the bolus insert has a bolus thickness to fill the difference between the second thickness and the first thickness within the negative space.

[0060] 11. According to the system described in any of the preceding clauses, wherein the component is an annular shroud of a gas turbine engine, the annular shroud having a flange extending around a radially outer edge and defining the negative space, and wherein the negative space is annular.

[0061] 12. According to the system described in any of the preceding clauses, wherein the bolus insert is arcuate.

[0062] 13. According to the system described in any of the preceding clauses, wherein the component comprises a ceramic matrix composite (CMC) material.

[0063] 14. According to the system described in any of the preceding clauses, wherein the bolus insert is formed of aluminum.

[0064] 15. A method, comprising: positioning a bolus insert within a negative space defined by a component; and scanning the component having the bolus insert to create an image of the component.

[0065] 16. According to the method described in any of the preceding clauses, further comprising: positioning the component having the bolus insert between a radiographic source and a radiographic receiver.

[0066] 17. According to the method described in any of the preceding clauses, wherein scanning the component comprises directing an X-ray beam from the radiographic source to the component.

[0067] 18. According to the method described in any of the preceding clauses, further comprising: shaping the bolus insert to conform to the negative space of the component.

[0068] 19. According to the method described in any of the preceding clauses, further comprising: selecting a bolus material for the bolus insert.

[0069] 20. According to the method described in any of the preceding clauses, wherein the bolus material has a bolus material density within fifteen percent (15%) of a component material density of a component material forming the component.

[0070] 21. According to the method described in any of the preceding clauses, wherein scanning the component comprises imaging the component using a digital radiography imaging device.

[0071] 22. According to the method described in any of the preceding clauses, wherein scanning the component comprises imaging the component using a film radiography imaging device.

[0072] 23. According to the method described in any of the preceding clauses, wherein scanning the component comprises imaging the component using a computed tomography imaging device.

[0073] 24. A component imaging assembly includes: a component including a first portion having a first thickness and a second portion having a second thickness, the first thickness being greater than the second thickness; and a syringe insert positioned adjacent to the second portion, the syringe insert having a syringe thickness substantially similar to the difference between the first thickness and the second thickness, wherein the syringe insert has a syringe material density within fifteen percent (15%) of the component material density of the component.

[0074] The written description uses examples to disclose the preferred embodiments, including the best mode, and also enables any person skilled in the art to practice the subject matter, including making and using any device or system and performing any incorporated method. The patentable scope of the disclosed subject matter is defined by the claims and may include other examples that occur to those skilled in the art. If these other examples include structural elements that are identical to the literal language of the claims or if they include equivalent structural elements that are not materially different from the literal language of the claims, then these other examples are intended to be within the scope of the claims.

Claims

1. A system for imaging a component that defines a negative space, characterized in that, The system includes: a component imaging assembly; a syringe insert; and an imaging device, wherein when the component is positioned within the imaging field of the imaging device to generate an image of the component, the syringe insert is capable of being positioned within the negative space of the component, wherein the negative space has a spatial geometry, and wherein the syringe insert has a syringe geometry that is at least partially complementary to the spatial geometry; and wherein the component is formed of a component material having a component material density, wherein the syringe insert is formed of a syringe material having a syringe material density, and wherein the syringe material density is within a density tolerance of the component material density, the density tolerance being fifteen percent, wherein the component has a first thickness in a first portion and a second thickness in a second portion adjacent to the negative space, the second thickness being less than the first thickness, and wherein the syringe insert has a syringe thickness to fill the difference between the second thickness and the first thickness within the negative space.

2. The system according to claim 1, wherein wherein the syringe material density is within a density tolerance of the component material density, the density tolerance being ten percent.

3. The system according to claim 1, characterized in that, wherein the imaging device is a radiographic imaging device.

4. The system according to claim 3, wherein wherein the radiographic imaging device includes a radiographic source and a radiographic receiver.

5. The system according to claim 4, wherein wherein the component is angled relative to the radiographic source.

6. The system according to claim 1, characterized in that wherein the component is positioned at an angle α relative to a horizontal direction orthogonal to the vertical direction.

7. The system according to claim 6, characterized in that, wherein the component is capable of rotating about an axis extending along the vertical direction to reposition the component within the imaging field.

8. The system according to claim 1, wherein wherein the component is an annular shroud of a gas turbine engine, the annular shroud having a flange that extends around a radially outer edge and defines the negative space, and wherein the negative space is annular.

9. The system according to claim 8, wherein wherein the syringe insert is arcuate.

10. The system according to claim 1, wherein wherein the component includes a ceramic matrix composite.

11. The system according to claim 1, characterized in that, wherein the syringe insert is formed of aluminum.

12. A method for imaging a component, characterized in that, including: positioning a syringe insert within a negative space defined by the component, wherein the negative space has a spatial geometry, and wherein the syringe insert has a syringe geometry that is at least partially complementary to the spatial geometry, wherein the component is formed of a component material having a component material density, wherein the syringe insert is formed of a syringe material having a syringe material density, and wherein the syringe material density is within a density tolerance of the component material density, the density tolerance being fifteen percent; and scanning the component having the syringe insert to create an image of the component, wherein the component has a first thickness in a first portion and a second thickness in a second portion adjacent to the negative space, the second thickness being less than the first thickness, and wherein the syringe insert has a syringe thickness to fill the difference between the second thickness and the first thickness within the negative space.

13. The method according to claim 12, characterized in that, further including: positioning the component having the syringe insert between a radiographic source and a radiographic receiver.

14. The method according to claim 13, wherein wherein scanning the component includes directing an X-ray beam from the radiographic source to the component.

15. The method according to claim 12, characterized in that, further including: Forming the bolus insert to conform at least in part to the negative space of the component.

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