Methods and systems for inspecting bonded structures
Patent Information
- Application Number
- JP2023000070
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-01-05
- Filing Date
- 2023-01-04
- Publication Date
- 2026-01-14
AI Technical Summary
Current methods for inspecting bond lines between joined structures, such as aircraft components, can weaken or break the bond, leading to the potential scrapping of the joined structure.
A method and system using phased array ultrasonic transducers to project acoustic waves at a non-zero angle into the bonded structure, determining the total refraction magnitude, and comparing it to a predefined value to detect out-of-tolerance conditions.
This approach effectively inspects bonded structures without weakening them, allowing for accurate detection of bond integrity and preventing scrap by identifying out-of-tolerance conditions.
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Abstract
Description
Technical Field
[0001] The present disclosure relates generally to joined structures, and more particularly to methods and systems for inspecting joined structures.
Background Art
[0002] Measuring the strength of a bond line between joined structures, such as layers of aircraft components, can be an important step before installing such components on an aircraft.
[0003] Currently, methods for inspecting bond lines between joined structures include the use of Laser Bond Inspection Detection. A drawback of Laser Bond Inspection Detection is that it can weaken and / or break the bond line of the joined structure. This can lead to the possibility that the joined structure has to be discarded after inspection. Therefore, those skilled in the art are continuing research and development in the field of inspecting joined structures.
Summary of the Invention
[0004] The following is a non-exhaustive list of examples of the subject matter according to the present disclosure, which may or may not be claimed.
[0005] A method for inspecting a joined structure is disclosed. The joined structure has a first structural member, a second structural member, and a bond line between the first structural member and the second structural member.
[0006] In one example, the disclosed method includes projecting an acoustic wave into the joined structure at an angle other than zero with respect to a normal axis defined by an outer surface of the first structural member. The method further includes identifying the magnitude of total refraction of the acoustic wave after the acoustic wave has passed through the joined structure. The method further includes comparing the magnitude of total refraction with a predefined value.
[0007] A method for inspecting a joined structure is also disclosed. The joined structure has a first structural member, a second structural member, and a joint line between the first structural member and the second structural member.
[0008] In one embodiment, the disclosed method includes acoustically coupling a first phased array ultrasonic transducer to the outer surface of a first structural member. The method further includes acoustically coupling a second phased array ultrasonic transducer to the outer surface of a second structural member. The method further includes projecting an acoustic wave from the first phased array ultrasonic transducer into the bonded structure at a non-zero angle with respect to a normal axis defined by the outer surface of the first structural member. The acoustic wave has a frequency in the range of about 1 MHz to about 20 MHz. The method further includes determining the magnitude of the total refraction of the acoustic wave received by the second phased array ultrasonic transducer. The method further includes comparing the magnitude of the total refraction to a predetermined value.
[0009] A system for inspecting a joined structure is also disclosed. The joined structure has a first structural member, a second structural member, and a joint line between the first structural member and the second structural member.
[0010] In one embodiment, the disclosed system includes a first phased array ultrasonic transducer acoustically coupled to the outer surface of a first structural member. The first phased array ultrasonic transducer is configured to project acoustic waves into the joined structure at a non-zero angle with respect to a normal axis defined by the outer surface of the first structural member. The system further includes a second phased array ultrasonic transducer acoustically coupled to the outer surface of a second structural member. The second phased array ultrasonic transducer is configured to receive acoustic waves after they have passed through the joined structure. The system further includes a processor that communicates with the first phased array ultrasonic transducer and the second phased array ultrasonic transducer. The processor is configured to determine the magnitude of the total refraction of the acoustic waves received by the second phased array ultrasonic transducer and to compare the magnitude of the total refraction with a predetermined value.
[0011] A method for inspecting a joined structure according to one aspect of the present disclosure, wherein the joined structure includes a first structural member, a second structural member, and a joint line between the first structural member and the second structural member, and the method is Projecting acoustic waves into the joined structures at a non-zero angle with respect to the normal axis defined by the outer surface of the first structural member, To determine the magnitude of the total refraction of an acoustic wave after it has passed through a joined structure, and This includes comparing the magnitude of total refraction with a predetermined value.
[0012] Advantageously, in this method, the acoustic wave is an ultrasonic acoustic wave.
[0013] Preferably, in this method, the acoustic wave has a frequency in the range of about 1 MHz to about 20 MHz.
[0014] Preferably, in this method, at least one of the first structural member and the second structural member is made of a metallic material. In this case, the acoustic waves have a frequency in the range of about 3 MHz to about 7 MHz.
[0015] Preferably, in this method, at least one of the first structural member and the second structural member includes a composite material. In this case, the acoustic waves have a frequency of about 1 MHz to about 5 MHz.
[0016] Preferably, in this method, at least one of the first structural member and the second structural member includes a composite material. In this case, the acoustic waves have a frequency of about 2 MHz to about 4 MHz.
[0017] Preferably, in this method, the acoustic wave is substantially a longitudinal acoustic wave.
[0018] Preferably, in this method, the non-zero angle is in the range of about 3 degrees to about 30 degrees.
[0019] Preferably, in this method, at least one of the first structural member and the second structural member includes a composite material.
[0020] Preferably, in this method, the acoustic wave is substantially a shear acoustic wave.
[0021] Preferably, in this method, the non-zero angle is in the range of about 20 degrees to about 80 degrees.
[0022] Preferably, in this method, the non-zero angle is in the range of about 30 degrees to about 70 degrees.
[0023] Preferably, in this method, at least one of the first structural member and the second structural member includes a metallic material.
[0024] Preferably, the method involves projecting acoustic waves into the joined structures by acoustically coupling a first phased array ultrasonic transducer with the outer surface of a first structural member.
[0025] Preferably, in the method, determining the magnitude of total refraction of the acoustic wave includes acoustically coupling a second phased array ultrasonic transducer to the outer surface of the second structural member.
[0026] Preferably, in the method, determining the magnitude of total refraction of the acoustic wave includes determining the position of the maximum amplitude signal in the second phased array ultrasonic transducer.
[0027] Preferably, in the method, an out-of-tolerance condition exists when the difference between the magnitude of total refraction and a predefined value exceeds a threshold value.
[0028] Preferably, the method further includes rejecting the joined structure when an out-of-tolerance condition exists.
[0029] Preferably, in the method, the joint line includes at least one adhesive layer.
[0030] Preferably, in the method, the joint line includes one of an epoxy adhesive, a polyurethane adhesive, and a reinforced acrylic adhesive.
[0031] Preferably, in the method, the first structural member and the second structural member are components of an aircraft.
[0032] A method for inspecting a joined structure according to another aspect of the present disclosure, the joined structure including a first structural member, a second structural member, and a joint line between the first structural member and the second structural member, the method comprising: Acoustically coupling a first phased array ultrasonic transducer to the outer surface of the first structural member, Acoustically coupling a second phased array ultrasonic transducer to the outer surface of the second structural member, Projecting acoustic waves from a first phased array ultrasonic transducer into a joined structure at a non-zero angle with respect to a normal axis defined by the outer surface of a first structural member, wherein the acoustic waves have a frequency in the range of approximately 1 MHz to approximately 20 MHz. To determine the magnitude of the total refraction of the acoustic wave received by the second phased array ultrasonic transducer, and This includes comparing the magnitude of total refraction with a predetermined value.
[0033] A system for inspecting a joined structure according to yet another aspect of the present disclosure, wherein the joined structure includes a first structural member, a second structural member, and a joint line between the first structural member and the second structural member, and the system is A first phased array ultrasonic transducer acoustically coupled to the outer surface of a first structural member, the first phased array ultrasonic transducer configured to project acoustic waves into the bonded structure at a non-zero angle with respect to a normal axis defined by the outer surface of the first structural member, A second phased array ultrasonic transducer acoustically coupled to the outer surface of a second structural member, the second phased array ultrasonic transducer configured to receive acoustic waves after they have passed through the coupled structure, and The system comprises a processor that communicates with a first phased array ultrasonic transducer and a second phased array ultrasonic transducer, and the processor To determine the magnitude of the total refraction of the acoustic wave received by the second phased array ultrasonic transducer, and It is configured to perform the task of comparing the magnitude of total refraction with a predetermined value.
[0034] Advantageously, in this system, the first phased array ultrasonic transducer is configured to project ultrasonic acoustic waves.
[0035] Preferably, in the system, the first phased array ultrasonic transducer is configured to project acoustic waves having a frequency in the range of about 1 MHz to about 20 MHz.
[0036] Preferably, in the system, the first phased array ultrasonic transducer is configured to project acoustic waves having a frequency in the range of about 3 MHz to about 7 MHz.
[0037] Preferably, in the system, the first phased array ultrasonic transducer is configured to project substantially longitudinal acoustic waves.
[0038] Preferably, in the system, the non-zero angle is in the range of about 3 degrees to about 30 degrees.
[0039] Preferably, in the system, the first phased array ultrasonic transducer is configured to project substantially transverse acoustic waves.
[0040] Preferably, in the system, the non-zero angle is in the range of about 30 degrees to about 70 degrees. [Brief explanation of the drawing]
[0041] [Figure 1] This is a flowchart of a method for inspecting joined structures. [Figure 2] This is a flowchart of a method for inspecting joined structures. [Figure 3] This is a schematic cross-sectional view of a system for inspecting joined structures. [Figure 4] This is a schematic cross-sectional view of a system for inspecting joined structures. [Figure 5] This is a flowchart of a block diagram for aircraft manufacturing and maintenance methods. [Figure 6] This is a schematic diagram of an aircraft. [Modes for carrying out the invention]
[0042] The following detailed description refers to the accompanying drawings, which illustrate specific embodiments described herein. Other embodiments having various structures and operations do not deviate from the scope of this disclosure. Similar reference numerals may represent the same features, elements, or components in different drawings.
[0043] Exemplary and non-exclusive embodiments of the subject matter of this disclosure, which may or may not be patentable, are provided below. Where the “Embodiment” is used herein, it means that one or more features, structures, elements, components, properties, and / or operating steps described in relation to such embodiment are included in at least one embodiment and / or representation of the subject matter of this disclosure. Thus, throughout this disclosure, the phrases “an example,” “another example,” “an example,” and similar wording may, but may not, refer to the same example. Furthermore, the subject matter of the invention characterizing any one example may, or may not, include the subject matter of the invention characterizing any other example. Furthermore, the subject matter characterizing any one embodiment may, but may not, be combined with the subject matter characterizing any of the other embodiments.
[0044] The disclosed system 100 (Figures 3 and 4), method 200 (Figure 1), and method 300 (Figure 2) utilize known impedance values and associated sound refraction values across various materials, specifically composite materials, metallic materials, and adhesives for joining these materials. Using these values as predetermined thresholds, system 100, method 200, and method 300 compare actual values collected across the joined structures to identify when an out-of-bounds condition 174 exists. For example, if the joint line 160 in the area of interest along the joined structure 110 changes, the resulting refraction angle changes, which indicates a potential out-of-bounds condition 174.
[0045] Referring to Figure 1, a method 200 for inspecting a joined structure 110 is disclosed. The joined structure 110 includes a first structural member 120, a second structural member 140, and a joint line 160 between the first structural member 120 and the second structural member 140. The first structural member 120 and the second structural member 140 may be components of an aircraft 1102, as shown in Figure 6. In one embodiment, the joint line 160 includes at least one adhesive layer 162. In another embodiment, the joint line 160 includes one of epoxy adhesive, polyurethane adhesive, and reinforced acrylic adhesive.
[0046] Each of the first structural member 120 and the second structural member 140 may contain any material suitable for its intended use. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 contains a metallic material. In another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material. In yet another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material, and the remaining structural member contains a metallic material. In yet another embodiment, both the first structural member 120 and the second structural member 140 may contain a metallic material. Furthermore, both the first structural member 120 and the second structural member 140 may contain a composite material.
[0047] As shown in Figure 1, the method 200 of the present disclosure includes the step 210 of projecting an acoustic wave 150 into a joined structure 110 at a non-zero angle T with respect to a normal axis A defined by the outer surface 108 of the first structural member 120. In one or more embodiments, projecting the acoustic wave 150 into the joined structure 110 210 includes acoustically coupling a first phased array ultrasonic transducer 102 with the outer surface 108 of the first structural member 120. In one or more embodiments, the first phased array ultrasonic transducer 102 includes a single-element ultrasound.
[0048] The non-zero angle T may depend on several factors, including the material composition of the first structural member 120 and the second structural member 140, the material composition of the joint line 160, and the type of acoustic wave 150 projected onto the joined structure 110. In one or more embodiments, the non-zero angle T is in the range of about 20 degrees to about 80 degrees. In another embodiment, the non-zero angle T is in the range of about 3 degrees to about 30 degrees. In yet another embodiment, the non-zero angle T is in the range of about 30 degrees to about 70 degrees.
[0049] Any type of acoustic wave 150 may be used to inspect and detect out-of-bounds conditions 174. In one embodiment, the acoustic wave 150 is an ultrasonic acoustic wave 152. In another embodiment, for example, when a composite substrate is used, the acoustic wave 150 is substantially a longitudinal acoustic wave 154. In yet another embodiment, for example, when a metal substrate is used, the acoustic wave 150 is substantially a transverse acoustic wave 156. The non-zero angle T may depend on the type of acoustic wave 150. For example, substantially a transverse acoustic wave 156 may have a non-zero angle T in the range of about 30 to about 70 degrees, while substantially a longitudinal acoustic wave 154 may have a non-zero angle T in the range of about 3 to about 30 degrees.
[0050] The acoustic wave 150 may have a frequency in the range of about 1 MHz to about 20 MHz. In one embodiment, the acoustic wave 150 has a frequency in the range of about 3 MHz to about 7 MHz. In another embodiment, the acoustic wave 150 has a frequency in the range of about 1 MHz to about 5 MHz. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 includes a composite material, and the acoustic wave 150 has a frequency in the range of about 2 MHz to about 4 MHz.
[0051] Referring still to Figure 1, method 200 further includes a step 220 of determining the magnitude of the total refraction 170 of the acoustic wave 150 after it has passed through the bonded structure 110. In one embodiment, determining the magnitude of the total refraction 170 of the acoustic wave 150 220 may include determining the location of the maximum amplitude signal within the second phased array ultrasonic transducer 104. In another embodiment, determining the magnitude of the total refraction 170 of the acoustic wave 150 220 may include acoustically coupling the second phased array ultrasonic transducer 104 with the outer surface 118 of the second structural member 140.
[0052] Referring still to Figure 1, method 200 further includes step 230 of comparing the magnitude of total refraction 170 with a predetermined value 172. The comparison 230 helps detect the presence of an out-of-range condition 174. In one embodiment, an out-of-range condition 174 exists when the difference between the magnitude of total refraction 170 and the predetermined value 172 exceeds a threshold. The threshold may be based on a value outside a predetermined tolerance range.
[0053] Referring still to Figure 1, method 200 may further include step 240 of rejecting the joined structure 110 when an unacceptable condition 174 exists. If rejected 240, the joined structure 110 may be subjected to further processing or disposal depending on the reason for rejection 240.
[0054] Referring to Figure 2, a method 300 for inspecting a joined structure 110 is disclosed. The joined structure 110 includes a first structural member 120, a second structural member 140, and a joint line 160 between the first structural member 120 and the second structural member 140. The first structural member 120 and the second structural member 140 may be components of an aircraft 1102 (see Figure 6). In one embodiment, the joint line 160 includes at least one adhesive layer 162. In another embodiment, the joint line 160 includes one of epoxy adhesive, polyurethane adhesive, and reinforced acrylic adhesive.
[0055] Each of the first structural member 120 and the second structural member 140 may contain any material suitable for its intended use. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 contains a metallic material. In another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material. In yet another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material, and the remaining structural member contains a metallic material. In yet another embodiment, both the first structural member 120 and the second structural member 140 may contain a metallic material. Furthermore, both the first structural member 120 and the second structural member 140 may contain a composite material.
[0056] Referring again to Figure 2, in one or more embodiments, method 300 includes acoustically coupling a first phased array ultrasonic transducer 102 to the outer surface 108 of a first structural member 120 310. Method 300 further includes acoustically coupling a second phased array ultrasonic transducer 104 to the outer surface 118 of a second structural member 140 320.
[0057] Referring again to Figure 2, method 300 includes step 330 of projecting acoustic waves 150 from a first phased array ultrasonic transducer 102 into a joined structure 110 at a non-zero angle T with respect to a normal axis A defined by the outer surface 108 of the first structural member 120. In one or more embodiments, the first phased array ultrasonic transducer 102 includes a single-element ultrasonic transducer.
[0058] The non-zero angle T may depend on several factors, including the material composition of the first structural member 120 and the second structural member 140, the material composition of the joint line 160, and the type of acoustic wave 150 projected onto the joined structure 110. In one or more embodiments, the non-zero angle T is in the range of about 20 degrees to about 80 degrees. In another embodiment, the non-zero angle T is in the range of about 3 degrees to about 30 degrees. In yet another embodiment, the non-zero angle T is in the range of about 30 degrees to about 70 degrees.
[0059] Any type of acoustic wave 150 may be used to inspect and detect out-of-bounds conditions 174. In one embodiment, the acoustic wave 150 is an ultrasonic acoustic wave 152. In another embodiment, the acoustic wave 150 is substantially a longitudinal acoustic wave 154. In yet another embodiment, the acoustic wave 150 is substantially a transverse acoustic wave 156. The non-zero angle T may depend on the type of acoustic wave 150. For example, substantially a transverse acoustic wave 156 may have a non-zero angle T in the range of about 30 to about 70 degrees, while substantially a longitudinal acoustic wave 154 may have a non-zero angle T in the range of about 3 to about 30 degrees.
[0060] The acoustic wave 150 may have a frequency in the range of about 1 MHz to about 20 MHz. In one embodiment, the acoustic wave 150 has a frequency in the range of about 3 MHz to about 7 MHz. In another embodiment, the acoustic wave 150 has a frequency in the range of about 1 MHz to about 5 MHz. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 includes a composite material, and the acoustic wave 150 has a frequency in the range of about 2 MHz to about 4 MHz.
[0061] Referring still to Figure 2, method 300 includes the step 340 of determining the magnitude of the total refraction 170 of the acoustic wave 150 received by the second phased array ultrasonic transducer 104. In one embodiment, determining the magnitude of the total refraction 170 of the acoustic wave 150 340 may include determining the location of the maximum amplitude signal within the second phased array ultrasonic transducer 104. In another embodiment, determining the magnitude of the total refraction 170 of the acoustic wave 150 340 may include acoustically coupling the second phased array ultrasonic transducer 104 with the outer surface 118 of the second structural member 140.
[0062] Referring still to Figure 2, method 300 includes step 350 of comparing the magnitude of total refraction 170 with a predetermined value 172. The comparison 350 helps detect the presence of an out-of-range condition 174. In one embodiment, an out-of-range condition 174 exists when the difference between the magnitude of total refraction 170 and the predetermined value 172 exceeds a threshold. The threshold may be based on a value outside a predetermined tolerance range.
[0063] Referring to Figures 3 and 4, a system 100 for inspecting a joined structure 110 is disclosed. The joined structure 110 includes a first structural member 120, a second structural member 140, and a joint line 160 between the first structural member 120 and the second structural member 140. The first structural member 120 and the second structural member 140 may be components of an aircraft 1102 (see Figure 6). In one embodiment, the joint line 160 includes at least one adhesive layer 162. In another embodiment, the joint line 160 includes one of epoxy adhesive, polyurethane adhesive, and reinforced acrylic adhesive.
[0064] Each of the first structural member 120 and the second structural member 140 may contain any material suitable for its intended use. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 contains a metallic material. In another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material. In yet another embodiment, at least one of the first structural member 120 and the second structural member 140 contains a composite material, and the remaining structural member contains a metallic material. In yet another embodiment, both the first structural member 120 and the second structural member 140 may contain a metallic material. Furthermore, both the first structural member 120 and the second structural member 140 may contain a composite material.
[0065] In one or more embodiments, the system 100 includes a first phased array ultrasonic transducer 102 acoustically coupled to the outer surface 108 of a first structural member 120. In one embodiment, the first phased array ultrasonic transducer 102 is configured to project acoustic waves 150 into the bonded structure 110 at a non-zero angle T with respect to a normal axis A defined by the outer surface 108 of the first structural member 120.
[0066] The non-zero angle T may depend on several factors, including the material composition of the first structural member 120 and the second structural member 140, the material composition of the joint line 160, and the type of acoustic wave 150 projected onto the joined structure 110. In one or more embodiments, the non-zero angle T is in the range of about 20 degrees to about 80 degrees. In another embodiment, the non-zero angle T is in the range of about 3 degrees to about 30 degrees. In yet another embodiment, the non-zero angle T is in the range of about 30 degrees to about 70 degrees.
[0067] Any type of acoustic wave 150 may be used to inspect and detect out-of-bounds conditions 174. In one embodiment, the acoustic wave 150 is an ultrasonic acoustic wave 152. In another embodiment, the acoustic wave 150 is substantially a longitudinal acoustic wave 154. In yet another embodiment, the acoustic wave 150 is substantially a transverse acoustic wave 156. A non-zero angle T may depend on the type of acoustic wave 150.
[0068] The acoustic wave 150 may have a frequency in the range of about 1 MHz to about 20 MHz. In one embodiment, the acoustic wave 150 has a frequency in the range of about 3 MHz to about 7 MHz. In another embodiment, the acoustic wave 150 has a frequency in the range of about 1 MHz to about 5 MHz. In one or more embodiments, at least one of the first structural member 120 and the second structural member 140 includes a composite material, and the acoustic wave 150 has a frequency in the range of about 2 MHz to about 4 MHz.
[0069] Referring again to Figures 3 and 4, the system 100 includes a second phased array ultrasonic transducer 104 acoustically coupled to the outer surface 118 of the second structural member 140. In one or more embodiments, the second phased array ultrasonic transducer 104 is configured to receive the acoustic waves 150 after they have passed through the bonded structure 110. Figure 3 shows the projection of the acoustic waves 150 at one angle, and Figure 4 shows the projection of the acoustic waves 150 at a different angle.
[0070] As shown in Figures 3 and 4, the system 100 further includes a processor 106 that communicates (e.g., by wired or wireless communication) with a first phased array ultrasonic transducer 102 and a second phased array ultrasonic transducer 104. The processor 106 is configured to determine the magnitude of the total refraction 170 of an acoustic wave 150 received by the second phased array ultrasonic transducer 104. The processor 106 is further configured to compare the magnitude of the total refraction 170 with a predetermined value 172. The processor 106 may be automated to automatically determine the magnitude of the total refraction 170 upon receiving the acoustic wave 150.
[0071] Multiple embodiments of this disclosure may be described in the context of an aircraft manufacturing and maintenance method 1100, as shown in Figure 5, and an aircraft 1102, as shown in Figure 6. In the pre-manufacturing stage, the maintenance method 1100 may include the specification and design of the aircraft 1102 (block 1104) and the procurement of materials (block 1106). In the manufacturing stage, the components and subassemblies of the aircraft 1102 may be manufactured (block 1108) and system integration (block 1110). The aircraft 1102 may then be licensed and delivered (block 1112) and put into operation (block 1114). During operation, the aircraft 1102 may be scheduled for periodic maintenance and upkeep (block 1116). Periodic maintenance and upkeep may include modifications, reconfigurations, and modifications of one or more systems of the aircraft 1102.
[0072] Each of the processes of Maintenance Method 1100 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, service organization, etc.
[0073] As shown in Figure 6, an aircraft 1102 manufactured by maintenance method 1100 may include a fuselage 1118 having several high-level systems 1120 and interior 1122. Examples of high-level systems 1120 include one or more of the propulsion system 1124, electrical system 1126, hydraulic system 1128, and environmental system 1130. Any number of other systems may also be included. Although an example from the aerospace industry has been given, the principles disclosed herein may also be applied to other industries such as the automotive industry. Therefore, the principles disclosed herein may be applied not only to aircraft 1102 but also to other vehicles such as land vehicles, sea vehicles, and space vehicles.
[0074] One or more structures and methods described herein may be used in one or more arbitrary stages of the manufacturing and maintenance method 1100. For example, components or subassemblies corresponding to the manufacture of components and subassemblies (block 1108) may be manufactured or produced in a similar manner to components or subassemblies manufactured during the operational period of the aircraft 1102 (block 1114). Also, one or more embodiments of one or more structures, one or more methods, or combinations thereof may be used in the manufacturing stages, i.e., production, manufacture of components and subassemblies (block 1108), and system integration (block 1110), for example, by substantially streamlining or reducing the cost of assembling the aircraft 1102. Similarly, one or more embodiments or combinations thereof that implement a structure or method may be used, for example, during the operational period of the aircraft 1102 (block 1114) and / or during maintenance and upkeep (block 1116).
[0075] Article 1. A method (200) for inspecting a joined structure (110), wherein the joined structure (110) includes a first structural member (120), a second structural member (140), and a joint line (160) between the first structural member (120) and the second structural member (140), and the method is Projecting acoustic waves (150) into the joined structure (110) at a non-zero angle (T) with respect to the normal axis (A) defined by the outer surface (108) of the first structural member (120) (210), After the acoustic wave (150) has passed through the joined structure (110), the magnitude of the total refraction (170) of the acoustic wave (150) is determined (220), and A method (200) comprising comparing the magnitude of the total refraction (170) with a predetermined value (172) (230).
[0076] Article 2. The method(200) according to Clause 1, wherein the acoustic wave (150) is an ultrasonic acoustic wave (152).
[0077] Article 3. The acoustic wave (150) has a frequency in the range of about 1 MHz to about 20 MHz, as described in Clause 1 or 2 (200).
[0078] Article 4. The method (200) according to any one of the first structural member (120) and the second structural member (140), wherein at least one of them is made of a metallic material and the acoustic wave (150) has a frequency in the range of about 3 MHz to about 7 MHz.
[0079] Article 5. The method (200) according to any one of the first structural member (120) and the second structural member (140), wherein at least one of them comprises a composite material and the acoustic wave (150) has a frequency in the range of about 1 MHz to about 5 MHz.
[0080] Article 6. The method (200) according to any one of the first structural member (120) and the second structural member (140), wherein at least one of them includes a composite material and the acoustic wave (150) has a frequency in the range of about 2 MHz to about 4 MHz.
[0081] Article 7. The method(200) described in any one of the clauses 1 to 6, wherein the acoustic wave(150) is substantially a longitudinal acoustic wave(154).
[0082] Article 8. The non-zero angle (T) is in the range of approximately 3 degrees to approximately 30 degrees, as described in Clause 7 (200).
[0083] Article 9. The method (200) according to Clause 8, wherein at least one of the first structural member (120) and the second structural member (140) includes a composite material.
[0084] Article 10. The method(200) described in any one of the clauses 1 to 9, wherein the acoustic wave(150) is substantially a transverse acoustic wave(156).
[0085] Article 11. The non-zero angle (T) is in the range of approximately 20 degrees to approximately 80 degrees, as described in the method of Clause 10 (200).
[0086] Article 12. The non-zero angle (T) is in the range of approximately 30 degrees to approximately 70 degrees, as described in Clause 11 (200).
[0087] Article 13. The method (200) according to clause 11 or 12, wherein at least one of the first structural member (120) and the second structural member (140) includes a metallic material.
[0088] Article 14. Projecting acoustic waves (150) into a joined structure (110) (210) is the method (200) according to any one of the clauses 1 to 13, which includes acoustically coupling a first phased array ultrasonic transducer (102) with the outer surface (108) of a first structural member (120).
[0089] Article 15. The method according to Clause 14 (200), wherein determining (220) the magnitude of the total refraction (170) of an acoustic wave (150) includes acoustically coupling a second phased array ultrasonic transducer (104) with the outer surface (118) of a second structural member (140).
[0090] Article 16. The method of Clause 15 (200), which includes determining the magnitude of the total refraction (170) of an acoustic wave (150) (220), and determining the location of the maximum amplitude signal in a second phased array ultrasonic transducer (104).
[0091] Article 17. The method (200) described in any one of clauses 1 to 16, wherein an out-of-range condition (174) exists when the difference between the magnitude of total refraction (170) and a predetermined value (172) exceeds a threshold.
[0092] Article 18. The method of the provisions of Article 17 (200), further including rejecting (240) a joined structure (110) when an unacceptable condition (174) exists.
[0093] Article 19. The bonding line (160) comprises at least one adhesive layer (162), as described in any one of the provisions 1 to 18 (200).
[0094] Article 20. The bonding line (160) comprises at least one of epoxy adhesive, polyurethane adhesive, and reinforced acrylic adhesive, as described in any one of Clauses 1 to 19 (200).
[0095] Article 21. A first structural member (120) and a second structural member (140) are components of an aircraft (1102), according to the method (200) described in any one of the clauses 1 to 20.
[0096] Article 22. A method (300) for inspecting a joined structure (110), wherein the joined structure (110) includes a first structural member (120), a second structural member (140), and a joint line (160) between the first structural member (120) and the second structural member (140), and the method is The first phased array ultrasonic transducer (102) is acoustically coupled (310) to the outer surface (108) of the first structural member (120). The second phased array ultrasonic transducer (104) is acoustically coupled (320) to the outer surface (118) of the second structural member (140). Projecting an acoustic wave (150) into a joined structure (110) from a first phased array ultrasonic transducer (102) at a non-zero angle (T) with respect to a normal axis (A) defined by the outer surface (108) of a first structural member (120), wherein the acoustic wave (150) has a frequency in the range of approximately 1 MHz to approximately 20 MHz. To determine the magnitude of the total refraction (170) of the acoustic wave (150) received by the second phased array ultrasonic transducer (104) (340), and A method (300) that includes comparing the magnitude of the total refraction (170) with a predetermined value (172) (350).
[0097] Article 23. A system (100) for inspecting a joined structure (110), wherein the joined structure (110) includes a first structural member (120), a second structural member (140), and a joint line (160) between the first structural member (120) and the second structural member (140), and the system is A first phased array ultrasonic transducer (102) acoustically coupled to the outer surface (108) of a first structural member (120), wherein the first phased array ultrasonic transducer (102) is configured to project acoustic waves (150) into the bonded structure (110) at a non-zero angle (T) with respect to a normal axis (A) defined by the outer surface (108) of the first structural member (120), A second phased array ultrasonic transducer (104) acoustically coupled to the outer surface (118) of a second structural member (140), the second phased array ultrasonic transducer (104) configured to receive acoustic waves (150) after they have passed through the bonded structure (110), and The system includes a processor (106) that communicates with a first phased array ultrasonic transducer (102) and a second phased array ultrasonic transducer (104), and the processor (106) To determine the magnitude of the total refraction (170) of the acoustic wave (150) received by the second phased array ultrasonic transducer (104), and A system (100) is configured to perform the task of comparing the magnitude of total refraction (170) with a predetermined value (172).
[0098] Article 24. The system (100) described in Clause 23, wherein the first phased array ultrasonic transducer (102) is configured to project ultrasonic acoustic waves (152).
[0099] Article 25. The system (100) according to Clause 23 or 24, wherein the first phased array ultrasonic transducer (102) is configured to project acoustic waves (150) having frequencies in the range of about 1 MHz to about 20 MHz.
[0100] Article 26. A first phased array ultrasonic transducer (102) is configured to project acoustic waves (150) having frequencies in the range of about 3 MHz to about 7 MHz, in the system (100) described in any one of clauses 23 to 25.
[0101] Article 27. A system (100) according to any one of the clauses 23 to 26, wherein the first phased array ultrasonic transducer (102) is configured to project substantially longitudinal acoustic waves (154).
[0102] Article 28. The non-zero angle (T) is in the range of approximately 3 degrees to approximately 30 degrees, as described in the system (100) in Clause 27.
[0103] Article 29. A system (100) according to any one of the clauses 23 to 28, wherein the first phased array ultrasonic transducer (102) is configured to project substantially transverse acoustic waves (156).
[0104] Article 30. The non-zero angle (T) is in the range of approximately 30 degrees to approximately 70 degrees, as described in the system (100) in Clause 29.
[0105] Various embodiments of the (one or more) structures and (one or more) methods disclosed herein include a variety of components, features, and functions. It should be understood that various embodiments of the (one or more) devices and (one or more) methods disclosed herein may include, in any combination, any of the components, features, and functions of any of the other multiple embodiments of the (one or more) devices and (one or more) methods disclosed herein, and all potential such components and functions are intended to be included within the scope of this disclosure.
[0106] Using the above description and the teachings presented in the accompanying drawings, a number of modifications to the examples specified herein will be conceivable to those skilled in the art to whom this disclosure relates.
[0107] Therefore, it should be understood that this disclosure is not limited to the specific examples illustrated, and that variations and other examples are intended to be included in the accompanying claims. Furthermore, while the embodiments of this disclosure are described in light of specific exemplary combinations of elements and / or functions in the foregoing description and the accompanying drawings, it should be understood that alternative embodiments may provide different combinations of elements and / or functions without departing from the scope of the accompanying claims. Accordingly, the reference numbers in parentheses in the accompanying claims are provided for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided in this disclosure.
Claims
1. A method (200) for inspecting a bonded structure (110), the bonded structure (110) including a first structural member (120), a second structural member (140), and a bond line (160) between the first structural member (120) and the second structural member (140), the method comprising: projecting (210) an acoustic wave (150) into the joined structure (110) at a non-zero angle (T) relative to a normal axis (A) defined by the outer surface (108) of the first structural member (120); determining (220) the magnitude of the total refraction (170) of the acoustic wave (150) after it passes through the bonded structure (110); and A method (200) comprising comparing (230) the magnitude of the total refraction (170) to a predefined value (172).
2. The method (200) of claim 1, wherein the acoustic waves (150) are ultrasonic acoustic waves (152).
3. The method (200) of claim 1 or 2, wherein the acoustic waves (150) have a frequency in the range of about 1 MHz to about 20 MHz.
4. 2. The method of claim 1, wherein at least one of the first structural member and the second structural member comprises a metallic material, and the acoustic wave has a frequency in a range from about 3 MHz to about 7 MHz.
5. 10. The method of claim 1, wherein at least one of the first structural member and the second structural member comprises a composite material, and the acoustic wave has a frequency in a range from about 1 MHz to about 5 MHz.
6. 10. The method of claim 1, wherein at least one of the first structural member and the second structural member comprises a composite material, and the acoustic wave has a frequency in a range from about 2 MHz to about 4 MHz.
7. The method (200) of claim 1, wherein the acoustic waves (150) are substantially longitudinal acoustic waves (154).
8. 8. The method (200) of claim 7, wherein the non-zero angle (T) ranges from about 3 degrees to about 30 degrees.
9. 10. The method of claim 1, wherein the acoustic wave is a substantially shear acoustic wave, and the non-zero angle ranges from about 20 degrees to about 80 degrees.
10. 2. The method of claim 1, wherein an out-of-tolerance condition exists when a difference between the magnitude of the total refraction and the predefined value exceeds a threshold value.
11. 1. A system (100) for inspecting a bonded structure (110), the bonded structure (110) including a first structural member (120), a second structural member (140), and a bond line (160) between the first structural member (120) and the second structural member (140), the system comprising: a first phased array ultrasonic transducer (102) acoustically coupled to an outer surface (108) of the first structural member (120), the first phased array ultrasonic transducer (102) configured to project acoustic waves (150) into the joined structure (110) at a non-zero angle (T) relative to a normal axis (A) defined by the outer surface (108) of the first structural member (120); a second phased array ultrasonic transducer (104) acoustically coupled to the outer surface (118) of the second structural member (140), the second phased array ultrasonic transducer (104) configured to receive the acoustic waves (150) after they pass through the joined structure (110); a processor (106) in communication with the first phased array ultrasonic transducer (102) and the second phased array ultrasonic transducer (104), the processor (106) comprising: determining a magnitude of total refraction (170) of the acoustic wave (150) received by the second phased array ultrasonic transducer (104); and comparing the magnitude of the total refraction (170) with a predefined value (172).
12. The system (100) of claim 11, wherein the first phased array ultrasonic transducer (102) is configured to project ultrasonic acoustic waves (152).
13. 13. The system (100) of claim 11 or 12, wherein the first phased array ultrasonic transducer (102) is configured to project acoustic waves (150) having a frequency in a range of about 1 MHz to about 20 MHz.
14. 12. The system of claim 11, wherein the first phased array ultrasonic transducer is configured to project acoustic waves having a frequency in a range of about 3 MHz to about 7 MHz.
15. The system (100) of claim 11, wherein the first phased array ultrasonic transducer (102) is configured to project substantially longitudinal acoustic waves (154).