Probe devices, systems, and methods used for non-destructive evaluation

Abstract

A probe device for use in non-destructive evaluation of a specimen comprises a transducer configuration configured and / or operable to direct an ultrasonic beam toward the specimen, a compliant element configured to engage with the specimen, and an intermediate member interposed between the transducer configuration and the compliant element. The intermediate member and the compliant element are positioned to define an interface between them. In some embodiments, the intermediate member and the compliant element are configured and / or operable to hold a fluid located at the interface between the intermediate member and the compliant element. In other embodiments, the probe device is configured and / or operable to control the tilt angle of the compliant element to reduce deviations in the ultrasonic beam propagating through the specimen.

Description

Technical Field

[0001] The present disclosure relates to a probe device, a system, and a method for non-destructive evaluation of a subject and for use in non-destructive evaluation of a subject.

Background Art

[0002] Non-destructive evaluation (NDE) techniques are widely used across a broad range of industrial fields to determine the characteristics, condition, integrity, and / or behavior of objects such as machines, components, or materials.

[0003] As the name indicates, unlike conventional testing techniques, in NDE techniques, the subject is not significantly damaged or altered by the evaluation, so the evaluation can be performed on an object that can subsequently be put into use. In fact, in some cases, NDE techniques can be used to determine the characteristics, condition, integrity, and / or behavior of an object during use.

[0004] One particular application of NDE is in the field of weld testing, and due to the non-destructive nature of NDE equipment and techniques, the quality of a weld can be evaluated before and / or during use. However, while NDE techniques offer important advantages over conventional testing techniques, with conventional NDE techniques, it is necessary to wait for all layers of the weld to be deposited and for the weld to cool to ambient temperature, resulting in rework requirements and / or reduced throughput.

[0005] More recently, NDE equipment and techniques have been developed that aim to evaluate welds during and / or immediately after the welding process itself, rather than waiting for all layers of the weld to be deposited and the weld to cool to ambient temperature. For example, conventional NDE techniques require waiting for each individual weld pass or layer to be completed and for the weld pass or layer to cool to ambient temperature, resulting in increased time required to complete the entire weld and increased energy costs associated with repeated heating and cooling cycles. It is well understood that the quality of a given weld depends on several variables present during and / or immediately after the welding process, and deviations in one or more variables beyond set limits often result in reduced weld quality, and in extreme cases, unsuitable welds. While automation allows for a greater degree of control over the variables affecting the welding process, in-process NDE offers the possibility of evaluating weld quality during and / or immediately after the welding process, and / or the possibility of better controlling the welding process to ensure weld quality.

[0006] While NDE technology offers significant advantages over conventional testing techniques, conventional NDE techniques have limitations when dealing with objects at temperatures above ambient temperature, as well as in terms of throughput.

[0007] Significant technical challenges still exist when using NDE equipment and / or techniques for in-process welding testing.

[0008] Another application of NDE lies in the field of composite material testing. Due to the non-destructive nature of NDE equipment and technology, the quality of composite materials and composite component parts can be evaluated before and / or during use.

[0009] The use of NDE equipment and / or techniques for composite material testing during the manufacturing process presents similar technical challenges to those discussed above in relation to in-process welding testing. [Overview of the project]

[0010] Aspects of this disclosure relate to probe devices used for non-destructive evaluation of a subject, and methods for non-destructive evaluation of one or more subjects.

[0011] According to a first aspect, a probe device is provided for use in non-destructive evaluation of a subject, the probe device comprising a transducer configuration configured and / or operable to direct an ultrasonic beam toward a subject, a compliant (flexible) element configured to engage with the subject, and an intermediate member interposed between the transducer configuration and the compliant element, the intermediate member and the compliant element being positioned to define an interface between them, and at least one of the intermediate member and the compliant element being configured and / or operable to hold a fluid positioned at the interface between the intermediate member and the compliant element.

[0012] During use, the probe device may be placed on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0013] Probe devices offer several advantages over conventional equipment.

[0014] For example, the probe device may eliminate or at least mitigate the possibility of fluid being discharged from the interface between the intermediate member and the compliant element during use, which is particularly, but not limited to, caused by the load force biasing the intermediate member to engage with the compliant element, pushing fluid out from the interface. This has the advantage of maintaining a cooling effect at the interface, which in turn may facilitate the use of the probe device at higher temperatures and / or the effective use of the probe device for extended periods at a given temperature.

[0015] Furthermore, by eliminating or at least mitigating the possibility of fluid discharge from the interface between the intermediate member and the compliant element, effective transmission of the ultrasonic beam from the transducer configuration to the compliant element and toward the subject is maintained. This may, in turn, allow the device to be subjected to a wider range and / or fluctuating load force. For example, the device may be subjected to a larger load force to better follow the subject without adversely affecting its ability to transmit the ultrasonic beam between the intermediate member and the compliant element and toward the subject. Alternatively, the device may be subjected to a smaller load force while eliminating or at least mitigating the possibility of fluid discharge from the interface, and the retention of fluid at the interface ensures effective transmission of the ultrasonic beam compared to conventional devices, without the conventional device relying on applying high load forces to the device.

[0016] The probe device may be configured and / or operable to facilitate dry bonding testing of the subject, i.e., without using a liquid couplant between the subject and the probe device.

[0017] Advantageously, dry bonding tests may facilitate a faster evaluation of the subject and / or eliminate the risk of liquid couplant contaminating the subject and / or the environment. However, it will be understood that in some embodiments, the probe device may use a liquid couplant such as a gel.

[0018] The probe device may be particularly applicable in the field of welding inspection, for example, but not limited to facilitating high-temperature compliant welding inspection not only on welds after and / or in use, but also during and / or immediately after the welding process, thereby enabling better control of the welding process to ensure welding quality. This may, in turn, lead to the elimination or at least reduction of the need for rework, as well as the incidental benefits of improved process planning certainty and / or reduced manufacturing lead times.

[0019] For example, the probe device may enable non-destructive evaluation at high temperatures, e.g., up to 350°C, during the welding process. More specifically, but not limited to, this facilitates evaluation between passes in multi-pass welding, thereby eliminating or at least mitigating the risk that defects present in the initial passes remain undetected until all layers of the weld have been deposited, otherwise requiring extensive rework or scrapping of the part and / or repeated heating and cooling of the part, which could adversely affect the quality of the weld. Accordingly, the probe device may also reduce the energy costs associated with the repeated heating and cooling cycles.

[0020] Alternatively, probe devices may be particularly applicable to the inspection of objects constructed using additive manufacturing techniques. In particular, probe devices are considered to offer beneficial effects in the inspection of objects constructed using metal additive manufacturing, such as wire arc additive manufacturing (WAAM).

[0021] Metal additive manufacturing is a method of metal manufacturing that involves continuously adding multiple layers to produce a metal object. Metal additive manufacturing is different from subtractive methods, which form metal parts by removing material or by shaping material, such as by machining, milling, or forming.

[0022] As described above, the ability of the probe device to be configured to facilitate and / or operate in a manner that facilitates dry bonding testing of the object under test may allow for more rapid evaluation of any metal object manufactured via metal additive manufacturing, and / or eliminate the risk of liquid couplant contaminating the metal object under test. Furthermore, the ability of the device to facilitate high-temperature testing of metal objects, i.e., the ability of the device to facilitate high-temperature testing of metal objects not only after and / or during the metal additive manufacturing process, but also during and / or immediately after the metal additive manufacturing process, makes it possible to better control the metal additive manufacturing process and ensure the quality of the metal object. This may, in turn, lead to the elimination or at least reduction of the need for rework, and to provide incidental benefits in terms of improved process planning certainty and / or reduced manufacturing lead time.

[0023] Alternatively, probe devices may be particularly applicable in the inspection of composite materials.

[0024] Advantageously, the probe device may facilitate the inspection of composite material components while eliminating or at least mitigating the possibility of liquid contamination of the composite material components, as may occur in some prior art applications.

[0025] As described above, the probe device comprises a transducer configuration that is configured and / or operable to direct an ultrasonic beam toward the subject.

[0026] The transducer configuration may include one or more transducers. One or more of the transducers may include or be in the form of a piezoelectric transducer. Alternatively or additionally, one or more of the transducers may include or be in the form of an eddy current transducer. Alternatively or additionally, one or more of the transducers may include or be in the form of a capacitive transducer, such as a capacitive micromachined ultrasonic transducer (CMUT). Alternatively or additionally, one or more of the transducers may include or be in the form of a dry-coupled ultrasonic testing (DCUT) transducer. Alternatively or additionally, one or more of the transducers may include or be in the form of an electromagnetic acoustic transducer (EMAT).

[0027] The transducer configuration may include or be in the form of a transducer array. The transducer configuration may include one or more transducer arrays. In particular, the transducer configuration may include or be in the form of a phased array ultrasonic transducer (PAUT) configuration.

[0028] The transducer configuration may be configured and / or operable to transmit and / or receive an ultrasonic beam. One or more of the transducers of the transducer configuration may include or be in the form of a transmitter or radiator, a receiver, or a transceiver.

[0029] The probe device may comprise a driver device, may be coupled to a driver device, or may be operably associated with a driver device. The transducer configuration may be coupled to and / or operably associated with a driver device, such as an ultrasonic driver device. A driver device, such as an ultrasonic driver device, may be configured and / or operable to transmit pulses. The ultrasonic driver device may be configured and / or operable to transmit electrical pulses. The ultrasonic driver device may be configured and / or operable to transmit high voltage pulses. The ultrasonic driver may be configured and / or operable to transmit high voltage electrical pulses. The ultrasonic driver may be configured and / or operable to record signals corresponding to ultrasonic beams received by one or more receivers.

[0030] In use, the ultrasonic driver device transmits a high voltage electrical pulse, whereby one or more transmitters transmit ultrasonic beams. When one or more receivers receive the reflected ultrasonic beams, the ultrasonic driver device is assumed to receive the corresponding signals. The ultrasonic driver device is then assumed to record the received signals.

[0031] Alternatively or additionally, the ultrasonic driver device transmits a high voltage electrical pulse, whereby each of the one or more transmitters transmits an ultrasonic beam at an interval separate from each of the other transmitters, and the reflections from each of the transmitted ultrasonic beams are received by one or more receivers. When a plurality of receivers receive the reflected ultrasonic beams, the ultrasonic driver device receives the corresponding signals and the ultrasonic driver device is assumed to record them. The recorded data may then be utilized to perform an advanced reconstruction in order to generate constructive interference in the wavefront.

[0032] The ultrasonic driver device may comprise a processing system configured to interpret the electronic signals recorded by the ultrasonic driver device after reception of the reflected ultrasonic beams by one or more receivers, and may be coupled to and / or operably associated with the processing system.

[0033] The processing system, or at least a part of the processing system, may form part of an ultrasonic driver device.

[0034] The processing system, or a part of the processing system, may be coupled to or operably associated with an ultrasonic driver device. For example, the processing system may be located at one or more remote locations. The remote locations may include or be in the form of a mobile device such as a tablet or mobile phone. Alternatively or additionally, the remote locations may include or be in the form of a control room. Alternatively or additionally, the remote locations may include or be in the form of a data store such as an online data store.

[0035] The ultrasonic driver device may be configured to transmit information to a processing system. The ultrasonic driver device may also include a communication configuration configured to transmit electronic signals corresponding to ultrasonic beams received by one or more receivers to one or more remote locations. The communication configuration may be a bidirectional communication configuration or take the form thereof.

[0036] As described above, the probe device includes an intermediate member interposed between the transducer configuration and the compliant element.

[0037] The intermediate member may have a solid core or be in the form of a solid core.

[0038] The intermediate member may have a wedge-shaped portion or be in the form of a wedge.

[0039] Alternatively, the intermediate member may comprise or be in the form of a planar or substantially planar member, or may have other shapes.

[0040] The intermediate member may be constructed partially or entirely from a plastic material. The plastic material may comprise or be in the form of a thermoplastic material. In certain embodiments, the plastic material may comprise or be in the form of a polyetherimide, e.g., Ultem(R). Alternatively or additionally, the plastic material may comprise or be in the form of a polyimide, e.g., Vespel(R). The plastic material may comprise or be in the form of a polyamide-imide, e.g., Duratron(R).

[0041] Advantageously, the intermediate member provides high strength and high-temperature performance, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material components during and / or immediately after the manufacturing process.

[0042] The transducer configuration and intermediate members may together form a transducer assembly for the probe device.

[0043] At least one of the transducer assembly and the compliant element is configured and / or operable to hold a fluid located at the interface between the intermediate member and the compliant element.

[0044] As described above, the probe device includes a compliant element configured to be positioned between the intermediate member and the subject.

[0045] The compliant element may be constructed in part or as a whole from an elastomer material. The elastomer material may comprise or be in the form of a silicone rubber material. In certain embodiments, the compliant element may be constructed in part or as a whole from high-temperature silicone rubber. Alternatively or additionally, the compliant element may comprise a hydrogenated nitrile butadiene rubber (HNBR) material. The compliant element may comprise an ethylene propylene diene monomer (EPDM) material.

[0046] Advantageously, the compliant element can conform to the shape of the object and provides high strength and high-temperature performance, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material parts during and / or immediately after the manufacturing process.

[0047] The compliant element may comprise or be in the form of a cylindrical or substantially cylindrical element.

[0048] The probe device may be configured such that the compliant element moves relative to the intermediate member. For example, the probe device may be configured such that the compliant element rotates around the intermediate member and / or transducer configuration. In certain embodiments, the compliant element may include or be in the form of a rolling element. The compliant element may include or be in the form of a tire, wheel, etc.

[0049] The compliant element may define an internal volume, at least partially. The internal volume may comprise or be in the form of a chamber. The transducer configuration and / or intermediate members (e.g., transducer assembly) may be located within the internal volume.

[0050] Alternatively, the probe device may be configured so that the compliant element moves axially relative to the intermediate member.

[0051] The compliant element may comprise or be in the form of a planar or substantially planar element. For example, the compliant element may comprise or be in the form of a film.

[0052] The probe device may include a support structure. The support structure may include or be in the form of a mandrel. When in use, the mandrel may form the axle of the probe device.

[0053] The transducer configuration and / or intermediate members (e.g., transducer assemblies) may be supported on a mandrel, or for example, mounted on it. The transducer configuration and / or intermediate members (e.g., transducer assemblies) may be fixedly coupled to a mandrel, or for example, fixedly mounted on a mandrel.

[0054] The compliant element may be movably supported on a mandrel, for example, mounted on or coupled to the mandrel. In certain embodiments, the compliant element may be rotatably supported on a mandrel, for example, mounted on or coupled to the mandrel. The probe device may include a bearing arrangement for rotatably supporting the compliant element.

[0055] As described above, the intermediate member and the compliant element are arranged to define an interface between them, and at least one of the intermediate member and the compliant element is configured and / or operable to hold a fluid placed at the interface between the intermediate member and the compliant element.

[0056] The configuration of the intermediate member and / or compliant element that holds the fluid placed at the interface may take on several different forms.

[0057] For example, the configuration of intermediate members and / or compliant elements that hold fluids placed at an interface may include or be configured to have a surface treatment.

[0058] The surface treatment may be formed or otherwise provided on the distal surface of the intermediate member, i.e., the surface of the intermediate member that faces the compliant element during use.

[0059] The compliant element may be movably supported on a mandrel, for example, mounted on or coupled to the mandrel. In certain embodiments, the compliant element may be rotatably supported on a mandrel, for example, mounted on or coupled to the mandrel. The probe device may include a bearing arrangement for rotatably supporting the compliant element.

[0060] As described above, the intermediate member and the compliant element are arranged to define an interface between them, and at least one of the intermediate member and the compliant element is configured and / or operable to hold a fluid placed at the interface between the intermediate member and the compliant element.

[0061] The configuration of the intermediate member and / or compliant element that holds the fluid placed at the interface may take on several different forms.

[0062] For example, the configuration of intermediate members and / or compliant elements that hold fluids placed at an interface may include or be configured to have a surface treatment.

[0063] The surface treatment may be formed or otherwise provided on the distal surface of the intermediate member, i.e., the surface of the intermediate member that faces the compliant element during use.

[0064] The surface treatment may include, or be in the form of, one or more protrusions formed on or provided on the intermediate member, one or more ridges formed on or provided on the intermediate member, one or more grooves formed on or provided on the intermediate member, one or more channels formed on or provided on the intermediate member, and / or one or more bores formed on or provided on the intermediate member. The surface treatment may be formed by one or more processes such as milling, e.g., CNC milling, machining, e.g., laser machining, engraving, etching, e.g., acid etching, and / or sandblasting.

[0065] The one or more processes described above may be applied to the intermediate member.

[0066] The surface roughness of the intermediate member may be selected based on the frequency and / or wavelength of the ultrasonic beam.

[0067] For example, the surface roughness may be selected such that Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0068] Advantageously, this may minimize or at least reduce wavefront aberration.

[0069] Alternatively or additionally, the surface treatment may be formed or otherwise provided on the surface of the compliant element facing the intermediate member, i.e., on the surface of the compliant element that may become the upper or inner surface of the compliant element during use.

[0070] The surface treatment may include, or be in the form of, one or more protrusions formed on or provided on the compliant element, one or more ridges formed on or provided on the compliant element, one or more grooves formed on or provided on the compliant element, one or more channels formed on or provided on the compliant element, and / or one or more bores formed on or provided on the compliant element.

[0071] The surface treatment may be formed by one or more processes such as milling, e.g., CNC milling; machining, e.g., laser machining; engraving; etching, e.g., acid etching; and / or sandblasting.

[0072] The one or more processes described above may be applied to the compliant element and / or the mold used to form the compliant element.

[0073] The surface roughness of the compliant element may be selected based on the frequency and / or wavelength of the ultrasonic beam.

[0074] For example, the surface roughness may be selected such that Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0075] Advantageously, this may minimize or at least reduce wavefront aberration.

[0076] As described above, during use, the probe device may be placed on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0077] In some embodiments, the intermediate member and the compliant element may be reconfigurable from a first configuration in which they are spaced apart from each other to a second configuration in which, in response to an applied load, the intermediate member engages with the compliant element, for example, the second configuration preventing fluid from escaping from the interface.

[0078] Alternatively, the intermediate member and the compliant element may be arranged to always engage, and the intermediate member and the compliant element may be reconfigurable between a first configuration in which they engage with each other but allow fluid to escape within the interface, and a second configuration in which, in response to an applied load, for example, the intermediate member engages with the compliant element to prevent fluid from escaping within the interface.

[0079] The probe device may be reconfigurable from a first configuration in which the distal surface and the inner surface are separate to a second configuration in which the distal surface engages with the inner surface, and one or more protrusions on the distal surface and / or the inner surface each hold the fluid in place at the interface formed by the engagement between the distal surface and the inner surface.

[0080] The probe device may be equipped with an absorber.

[0081] The absorber may be coupled to and / or operably associated with the intermediate member. The absorber may be coupled to and / or operably associated with the outer wall of the intermediate member, i.e., the surface of the intermediate member that is positioned vertically or substantially vertically during use.

[0082] The absorber is configured and / or operable to absorb ultrasound.

[0083] Advantageously, the absorber may prevent undesirable reflected waves / signals from affecting the evaluation.

[0084] As described above, the fluid is placed within the probe device, including the fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0085] The probe device may include an inlet configuration. The inlet configuration may include one or more inlets.

[0086] The probe device may include an outlet configuration. The outlet configuration may include one or more outlets.

[0087] The inlet configuration may be coupled to and / or operably associated with the fluid configuration. The fluid configuration may be configured and / or operable to supply fluid for delivery at the interface between the intermediate member and the compliant element. The fluid configuration may be configured and / or operable to supply fluid for delivery at the interface via the inlet configuration.

[0088] The outlet configuration may be coupled to and / or operably associated with the fluid configuration. The fluid configuration may be configured and / or operable to remove fluid from the interface. The fluid configuration may be configured and / or operable to remove fluid from the interface via the outlet configuration.

[0089] The fluid configuration may be configured and / or operable to supply fluid to be supplied at the interface via the outlet configuration.

[0090] The fluid configuration may be configured and / or operable to remove fluid from the interface via the inlet configuration.

[0091] The fluid configuration may be configured and / or operable to simultaneously supply and remove fluid.

[0092] The fluid configuration may be configured and / or operable to sequentially supply and remove fluid.

[0093] The inlet and outlet configurations may consist of separate configurations or be in a similar form.

[0094] Alternatively, for example, if the fluid configuration is configured and / or operable to sequentially supply fluid and then sequentially remove fluid, the inlet and outlet configurations may have or be in the same arrangement.

[0095] The device may include a valve configuration. The valve configuration may be configured and / or operable to control the inflow and / or outflow of fluid.

[0096] The fluid configuration may include a cooling configuration, which may be coupled to and / or operably associated with the cooling configuration. The cooling configuration may be configured and / or operable to cool a fluid to be placed at the interface.

[0097] During use, the cooling configuration cools the fluid to be placed at the interface between the intermediate member and the compliant element. The fluid source then supplies the fluid to the internal volume of the compliant element via the inlet configuration, at which point the fluid is placed at the interface. The fluid, whose temperature has risen through the use of the probe device, is then removed from the internal volume of the compliant element by the fluid configuration via the outlet configuration. While removing the hot fluid from the internal volume, the fluid configuration may simultaneously supply cooled fluid to the internal volume via the cooling configuration to replace the removed hot fluid. The cooling configuration then cools the removed hot fluid, and the cooled fluid may be resupplied to the internal volume of the compliant element via the inlet configuration.

[0098] The fluid may be configured and / or operable to act as a coolant and / or internal coupling, which facilitates the transmission of ultrasound to the compliant element and to the subject.

[0099] The fluid may include or be in the form of a liquid.

[0100] The fluid may include or be in the form of a coolant.

[0101] The fluid may include or be in the form of a couplant.

[0102] The probe device may be configured and / or operable to control the tilt angle of a compliant element to reduce deviations in the ultrasonic beam propagating within the subject.

[0103] During use, the probe device may be positioned on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, the probe device is configured and / or operable to control the tilt angle of the compliant element to reduce deviations in the ultrasonic beam propagating through the subject.

[0104] It has been found that a 1-degree difference in the inclination of the inner and outer surfaces of a compliant element results in a much larger deviation in the ultrasonic beam path within the subject. For example, compliant elements often contain materials to which sound travels at a lower speed compared to the materials contained in the intermediate member and the subject, respectively. Therefore, as the ultrasonic beam propagates from the intermediate member to the compliant element, the beam is refracted, resulting in a significant change in the angle of the ultrasonic beam. A similar refraction process occurs as the beam propagates from the compliant element to the subject. If the inner and outer surfaces of the compliant element are kept parallel to each other, the angle of the ultrasonic beam path within the subject is unaffected.

[0105] Advantageously, the probe device compensates for deviations in the ultrasonic beam propagating within the subject, which occur due to the ultrasonic beam propagating through compliant elements whose inner and outer surfaces are non-parallel.

[0106] The probe device may be configured and / or operable to and / or operable to have an arrangement for controlling the tilt angle of a compliant element in order to reduce deviations in the ultrasonic beam propagating within the subject.

[0107] The probe device may include a passive configuration for controlling the tilt of the compliant element.

[0108] The probe device may include a guide configuration.

[0109] The guide configuration may be configured and / or operable as a movement limiter.

[0110] The guide configuration may include or be in the form of a mechanical jig, frame, etc.

[0111] The passive configuration may include one or more wheels. The one or more wheels may be configured and / or operable to control the alignment of compliant elements.

[0112] The probe device may be coupled to and / or operably associated with an active configuration for controlling the tilt of the compliant element.

[0113] The active configuration may include or be in the form of an actuator configuration.

[0114] The actuator configuration may include one or more actuators.

[0115] One or more actuators in the actuator configuration may include or be in the form of mechanical actuators.

[0116] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of fluid-driven actuators.

[0117] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of a robotic actuator, for example, a robotic arm.

[0118] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of pneumatic actuators.

[0119] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of electric actuators.

[0120] According to a second embodiment, a system is provided for use in non-destructive evaluation of a subject, the system comprising one or more probe devices according to the first embodiment.

[0121] According to a third aspect, a method for non-destructive evaluation is provided that uses the probe device of the first aspect or the system of the second aspect.

[0122] According to a fourth aspect, a probe device is provided for use in non-destructive evaluation of a subject, the probe device comprising a transducer configuration configured and / or operable to direct an ultrasonic beam toward a subject, a compliant element configured to engage with the subject, and an intermediate member interposed between the transducer configuration and the compliant element, the probe device being configured and / or operable to an arrangement for controlling the tilt angle of the compliant element to reduce deviations in the ultrasonic beam propagating within the subject, and / or being operable to such arrangement.

[0123] During use, the probe device may be positioned on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, the probe device is configured and / or operable to control the tilt angle of the compliant element to reduce deviations in the ultrasonic beam propagating through the subject.

[0124] It has been found that a 1-degree difference in the inclination of the inner and outer surfaces of a compliant element results in a much larger deviation in the ultrasonic beam path within the subject. For example, compliant elements often contain materials to which sound travels at a lower speed compared to the materials contained in the intermediate member and the subject, respectively. Therefore, as the ultrasonic beam propagates from the intermediate member to the compliant element, the beam is refracted, resulting in a significant change in the angle of the ultrasonic beam. A similar refraction process occurs as the beam propagates from the compliant element to the subject. If the inner and outer surfaces of the compliant element are kept parallel to each other, the angle of the ultrasonic beam path within the subject is unaffected.

[0125] Advantageously, the probe device compensates for deviations in the ultrasonic beam propagating within the subject, which occur due to the ultrasonic beam propagating through compliant elements whose inner and outer surfaces are non-parallel.

[0126] As described above, the probe device is configured and / or operable to an arrangement for controlling the tilt angle of compliant elements to reduce deviations in the ultrasonic beam propagating within the subject, and / or is operable to such an arrangement.

[0127] The probe device may be coupled to and / or operably associated with an active configuration for controlling the tilt of the compliant element.

[0128] The active configuration may include or be in the form of an actuator configuration.

[0129] The actuator configuration may include one or more actuators.

[0130] One or more actuators in the actuator configuration may include or be in the form of mechanical actuators.

[0131] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of fluid-driven actuators.

[0132] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of a robotic actuator, for example, a robotic arm.

[0133] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of pneumatic actuators.

[0134] Alternatively or additionally, one or more actuators in the actuator configuration may include or be in the form of electric actuators.

[0135] The probe device may include a passive configuration for controlling the tilt of the compliant element.

[0136] The probe device may include a guide configuration.

[0137] The guide configuration may be configured and / or operable as a movement limiter.

[0138] The passive configuration may include one or more wheels. The one or more wheels may be configured and / or operable to control the alignment of compliant elements.

[0139] The probe device may include a sensor configuration, be coupled to a sensor configuration, or be operably associated with a sensor configuration.

[0140] The sensor configuration may be configured and / or operable to measure the inclination of the compliant element. The sensor configuration may be configured and / or operable to measure the inclination of the inner and outer surfaces of the compliant element.

[0141] The sensor configuration may be configured and / or operable to transmit one or more output signals, including measurement data relating to the tilt of a compliant element, for example, the tilt of the inner and outer surfaces of the compliant element.

[0142] The sensor configuration may be configured and / or operable to measure the angle of the subject and / or the angle between the sensor configuration and the subject.

[0143] The sensor configuration may be calibrated according to the position of the subject.

[0144] The sensor configuration may comprise one or more sensors. The sensor configuration may comprise one or more non-contact distance measuring sensors. At least one of the sensors may comprise or be in the form of a laser profiler. Alternatively or additionally, at least one of the sensors may comprise or be in the form of an IR distance sensor. At least one of the sensors may comprise or be in the form of an ultrasonic distance sensor. At least one of the sensors may comprise or be in the form of a force sensor. At least one of the sensors may comprise or be in the form of a torque sensor.

[0145] The active configuration may include a sensor configuration. The active configuration may be configured and / or operable to adjust the tilt of the compliant element in accordance with the readings of the sensor configuration. The active configuration may be configured and / or operable to adjust the tilt of the compliant element in real time in accordance with the readings of the sensor configuration.

[0146] The sensor configuration may include, be coupled to, or be operably associated with a communication configuration for transmitting one or more output signals, for example, to a control system.

[0147] The communication configuration may include or be in the form of a wired communication configuration. Alternatively, the communication configuration may include or be in the form of a wireless communication configuration.

[0148] The one or more robotic actuators may be configured and / or operable to be controlled by an algorithm. The algorithm may control the one or more robotic actuators based on tilt data generated by a sensor configuration.

[0149] The intermediate member and the compliant element may be positioned to define an interface between them. At least one of the intermediate member and the compliant element may be configured and / or operable to hold a fluid placed at the interface between the intermediate member and the compliant element.

[0150] During use, the probe device may be placed on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0151] As described above, the probe device comprises a transducer configuration that is configured and / or operable to direct an ultrasonic beam toward the subject.

[0152] The transducer configuration may comprise one or more transducers. One or more transducers may comprise or be in the form of a piezoelectric transducer. Alternatively or additionally, one or more transducers may comprise or be in the form of an eddy current transducer. Alternatively or additionally, one or more transducers may comprise or be in the form of a capacitive transducer, such as a capacitive micromachining ultrasonic transducer (CMUT). Alternatively or additionally, one or more transducers may comprise or be in the form of a dry coupled ultrasonic test (DCUT) transducer. Alternatively or additionally, one or more transducers may comprise or be in the form of an electromagnetic acoustic transducer (EMAT).

[0153] The transducer configuration may include or be in the form of a transducer array. The transducer configuration may include one or more transducer arrays. In particular, the transducer configuration may include or be in the form of a phased array ultrasonic transducer (PAUT) configuration.

[0154] The transducer configuration may be configured and / or operable to transmit and / or receive an ultrasonic beam. One or more transducers in the transducer configuration may be in the form of a transmitter or radiator, receiver, transceiver, or transceiver.

[0155] The transducer configuration may be coupled to and / or operably associated with a driver device, such as an ultrasonic driver device. The driver device, such as an ultrasonic driver device, may be configured and / or operable to transmit pulses. The ultrasonic driver device may be configured and / or operable to transmit electrical pulses. The ultrasonic driver device may be configured and / or operable to transmit high-voltage pulses. The ultrasonic driver device may be configured and / or operable to transmit high-voltage electrical pulses. The ultrasonic driver may be configured and / or operable to record signals corresponding to ultrasonic beams received by one or more receivers.

[0156] During use, the ultrasonic driver device transmits a high-voltage electrical pulse, which causes one or more transmitters to transmit an ultrasonic beam. When one or more receivers receive the reflected ultrasonic beam, the ultrasonic driver device receives a corresponding signal. The ultrasonic driver device then records the received signal.

[0157] Alternatively or additionally, the ultrasonic driver device transmits high-voltage electrical pulses, thereby causing each of the one or more transmitters to transmit an ultrasonic beam at a separate interval from each of the other transmitters, and the reflection from each transmitted ultrasonic beam is received by one or more receivers. When multiple receivers receive the reflected ultrasonic beams, the ultrasonic driver device receives the corresponding signals, and the ultrasonic driver device shall record these. The recorded data may then be used to perform advanced reconstruction to generate constructive interference in the wavefront.

[0158] The ultrasonic driver device may include a processing system configured to interpret the electronic signals recorded by the ultrasonic driver device after the reception of reflected ultrasonic beams by one or more receivers, and may be coupled to and / or operably associated with the processing system.

[0159] The processing system, or at least a part of the processing system, may form part of an ultrasonic driver device.

[0160] The processing system, or a part of the processing system, may be coupled to or operably associated with an ultrasonic driver device. For example, the processing system may be located at one or more remote locations. The remote locations may include or be in the form of a mobile device such as a tablet or mobile phone. Alternatively or additionally, the remote locations may include or be in the form of a control room. Alternatively or additionally, the remote locations may include or be in the form of a data store such as an online data store.

[0161] The ultrasonic driver device may be configured to transmit information to a processing system. The ultrasonic driver device may also include a communication configuration configured to transmit electronic signals corresponding to ultrasonic beams received by one or more receivers to one or more remote locations. The communication configuration may be a bidirectional communication configuration or take the form thereof.

[0162] As described above, the probe device includes an intermediate member interposed between the transducer configuration and the compliant element.

[0163] The intermediate member may have a solid core or be in the form of a solid core.

[0164] The intermediate member may have a wedge-shaped portion or be in the form of a wedge.

[0165] Alternatively, the intermediate member may comprise or be in the form of a planar or substantially planar member, or may have other shapes.

[0166] The intermediate member may be constructed partially or entirely from a plastic material. The plastic material may comprise or be in the form of a thermoplastic material. In certain embodiments, the plastic material may comprise or be in the form of a polyetherimide, e.g., Ultem(R). Alternatively or additionally, the plastic material may comprise or be in the form of a polyimide, e.g., Vespel(R). The plastic material may comprise or be in the form of a polyamide-imide, e.g., Duratron(R).

[0167] Advantageously, the intermediate member provides high strength and high-temperature performance, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material components during and / or immediately after the manufacturing process.

[0168] The transducer configuration and intermediate members may together form a transducer assembly for the probe device.

[0169] At least one of the transducer assembly and the compliant element may be configured and / or operable to hold a fluid located at the interface between the intermediate member and the compliant element.

[0170] As described above, the probe device includes a compliant element configured to be positioned between the intermediate member and the subject.

[0171] The compliant element may be constructed in part or as a whole from an elastomer material. The elastomer material may comprise or be in the form of a silicone rubber material. In certain embodiments, the compliant element may be constructed in part or as a whole from high-temperature silicone rubber. Alternatively or additionally, the compliant element may comprise a hydrogenated nitrile butadiene rubber (HNBR) material. The compliant element may comprise an ethylene propylene diene monomer (EPDM) material.

[0172] Advantageously, the compliant element can conform to the shape of the object and provides high strength and high-temperature performance, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material parts during and / or immediately after the manufacturing process.

[0173] The compliant element may comprise or be in the form of a cylindrical or substantially cylindrical element.

[0174] The probe device may be configured such that the compliant element moves relative to the intermediate member. For example, the probe device may be configured such that the compliant element rotates around the intermediate member and / or transducer configuration. In certain embodiments, the compliant element may include or be in the form of a rolling element. The compliant element may include or be in the form of a tire, wheel, etc.

[0175] Alternatively, the compliant element may comprise or be in the form of a planar or substantially planar element. For example, the compliant element may comprise or be in the form of a film.

[0176] The probe device may be configured such that the compliant element moves axially relative to the intermediate member.

[0177] The compliant element may define an internal volume, at least partially. The internal volume may comprise or be in the form of a chamber. The transducer configuration and / or intermediate members (e.g., transducer assembly) may be located within the internal volume.

[0178] The probe device may include a support structure. The support structure may include or be in the form of a mandrel. When in use, the mandrel may form the axle of the probe device.

[0179] The transducer configuration and / or intermediate members (e.g., transducer assemblies) may be supported on a mandrel, or for example, mounted on it. The transducer configuration and / or intermediate members (e.g., transducer assemblies) may be fixedly coupled to a mandrel, or for example, fixedly mounted on a mandrel.

[0180] The compliant element may be movably supported on a mandrel, for example, mounted on or coupled to the mandrel. In certain embodiments, the compliant element may be rotatably supported on a mandrel, for example, mounted on or coupled to the mandrel. The probe device may include a bearing arrangement for rotatably supporting the compliant element.

[0181] As described above, the intermediate member and the compliant element are arranged to define an interface between them, and at least one of the intermediate member and the compliant element is configured and / or operable to hold a fluid placed at the interface between the intermediate member and the compliant element.

[0182] The configuration of the intermediate member and / or compliant element that holds the fluid placed at the interface may take on several different forms.

[0183] For example, the configuration of intermediate members and / or compliant elements that hold fluids placed at an interface may include or be configured to have a surface treatment.

[0184] The surface treatment may be formed or otherwise provided on the distal surface of the intermediate member, i.e., the surface of the intermediate member that faces the compliant element during use.

[0185] The surface treatment may include, or be in the form of, one or more protrusions formed on or provided on the intermediate member, one or more ridges formed on or provided on the intermediate member, one or more grooves formed on or provided on the intermediate member, one or more channels formed on or provided on the intermediate member, and / or one or more bores formed on or provided on the intermediate member. The surface treatment may be formed by one or more processes such as milling, e.g., CNC milling, machining, e.g., laser machining, engraving, etching, e.g., acid etching, and / or sandblasting.

[0186] The one or more processes described above may be applied to the intermediate member and / or the mold used to form the intermediate member.

[0187] The surface roughness of the intermediate member may be selected based on the frequency and / or wavelength of the ultrasonic beam.

[0188] For example, the surface roughness may be selected such that Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0189] Advantageously, this may minimize or at least reduce wavefront aberration.

[0190] Alternatively or additionally, the surface treatment may be formed or otherwise provided on the surface of the compliant element facing the intermediate member, i.e., on the surface of the compliant element that may become the upper or inner surface of the compliant element during use.

[0191] The surface treatment may include, or be in the form of, one or more protrusions formed on or provided on the compliant element, one or more ridges formed on or provided on the compliant element, one or more grooves formed on or provided on the compliant element, one or more channels formed on or provided on the compliant element, and / or one or more bores formed on or provided on the compliant element.

[0192] The surface treatment may be formed by one or more processes such as milling, e.g., CNC milling; machining, e.g., laser machining; engraving; etching, e.g., acid etching; and / or sandblasting.

[0193] The one or more processes described above may be applied to the compliant element and / or the mold used to form the compliant element.

[0194] The surface roughness of the compliant element may be selected based on the frequency and / or wavelength of the ultrasonic beam.

[0195] For example, the surface roughness may be selected such that Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0196] Advantageously, this may minimize or at least reduce wavefront aberration.

[0197] As described above, during use, the probe device may be placed on the subject, and the compliant element is subjected to a force that biases the compliant element to engage with or enhance the engagement with the subject. The transducer configuration is configured and / or operable to direct an ultrasonic beam toward the subject, and one or more characteristics of the reflected beam are detected by the transducer configuration and / or another detection arrangement to determine the characteristics, state, health and / or behavior of the subject. As further described below, a fluid is placed within the probe device, including a fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0198] In some embodiments, the intermediate member and the compliant element may be reconfigurable from a first configuration in which they are spaced apart from each other to a second configuration in which, in response to an applied load, the intermediate member engages with the compliant element, for example, the second configuration preventing fluid from escaping from the interface.

[0199] Alternatively, the intermediate member and the compliant element may be arranged to always engage, and the intermediate member and the compliant element may be reconfigurable between a first configuration in which they engage with each other but allow fluid to escape within the interface, and a second configuration in which, in response to an applied load, for example, the intermediate member engages with the compliant element to prevent fluid from escaping within the interface.

[0200] The probe device may be reconfigurable from a first configuration in which the distal surface and the inner surface are separate to a second configuration in which the distal surface engages with the inner surface, and one or more protrusions on the distal surface and / or the inner surface each hold the fluid in place at the interface formed by the engagement between the distal surface and the inner surface.

[0201] The probe device may be equipped with an absorber.

[0202] The absorber may be coupled to and / or operably associated with the intermediate member. The absorber may be coupled to and / or operably associated with the outer wall of the intermediate member, i.e., the surface of the intermediate member that is positioned vertically or substantially vertically during use.

[0203] The absorber is configured and / or operable to absorb ultrasound.

[0204] Advantageously, the absorber may prevent undesirable reflected waves / signals from affecting the evaluation.

[0205] As described above, the fluid is placed within the probe device, including the fluid at the interface between the intermediate member and the compliant element, which acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element and to the subject. In this probe device, one or both of the intermediate member and the compliant element are configured and / or operable to hold the fluid placed at the interface between the intermediate member and the compliant element.

[0206] The probe device may include an inlet configuration. The inlet configuration may include one or more inlets.

[0207] The probe device may include an outlet configuration. The outlet configuration may include one or more outlets.

[0208] The inlet configuration may be coupled to and / or operably associated with the fluid configuration. The fluid configuration may be configured and / or operable to supply fluid for delivery at the interface between the intermediate member and the compliant element. The fluid configuration may be configured and / or operable to supply fluid for delivery at the interface via the inlet configuration.

[0209] The outlet configuration may be coupled to and / or operably associated with the fluid configuration. The fluid configuration may be configured and / or operable to remove fluid from the interface. The fluid configuration may be configured and / or operable to remove fluid from the interface via the outlet configuration.

[0210] The fluid configuration may be configured and / or operable to supply fluid to be supplied at the interface via the outlet configuration.

[0211] The fluid configuration may be configured and / or operable to remove fluid from the interface via the inlet configuration.

[0212] The fluid configuration may be configured and / or operable to simultaneously supply and remove fluid.

[0213] The fluid configuration may be configured and / or operable to sequentially supply and remove fluid.

[0214] The inlet and outlet configurations may consist of separate configurations or be in a similar form.

[0215] Alternatively, for example, if the fluid configuration is configured and / or operable to sequentially supply fluid and then sequentially remove fluid, the inlet and outlet configurations may have or be in the same arrangement.

[0216] The device may include a valve configuration. The valve configuration may be configured and / or operable to control the inflow and / or outflow of fluid.

[0217] The fluid configuration may include a cooling configuration, which may be coupled to and / or operably associated with the cooling configuration. The cooling configuration may be configured and / or operable to cool a fluid to be placed at the interface.

[0218] During use, the cooling configuration cools the fluid to be placed at the interface between the intermediate member and the compliant element. The fluid source then supplies the fluid to the internal volume of the compliant element via the inlet configuration, at which point the fluid is placed at the interface. The fluid, whose temperature has risen through the use of the probe device, is then removed from the internal volume of the compliant element by the fluid configuration via the outlet configuration. While removing the hot fluid from the internal volume, the fluid configuration may simultaneously supply cooled fluid to the internal volume via the cooling configuration to replace the removed hot fluid. The cooling configuration then cools the removed hot fluid, and the cooled fluid may be resupplied to the internal volume of the compliant element via the inlet configuration.

[0219] The fluid may be configured and / or operable to act as a coolant and / or internal coupling, which facilitates the transmission of ultrasound to the compliant element and to the subject.

[0220] The fluid may include or be in the form of a liquid.

[0221] The fluid may include or be in the form of a coolant.

[0222] The fluid may include or be in the form of a couplant.

[0223] According to a fifth aspect, a system is provided for use in non-destructive evaluation of a subject, the system comprising one or more probe devices according to a fourth aspect.

[0224] The system may include an arrangement, which may be configured and / or operable to control the tilt angle of compliant elements to reduce deviations in the ultrasonic beam propagating within the subject. The arrangement may include or be in the form of an active configuration.

[0225] The system may include a control system, be coupled to a control system, or be operably associated with a control system.

[0226] In particular, the control system may be configured and / or operable to control the tilt of the compliant element. The control system may be configured to receive one or more output signals from the sensor configuration. The one or more output signals from the sensor configuration may form inputs to a position control algorithm under the control of the control system. The one or more output signals from the sensor configuration may form inputs to an imaging compensation algorithm under the control of the control system.

[0227] According to the sixth aspect, a method for non-destructive evaluation is provided that uses the probe device of the fourth aspect or the system of the fifth aspect.

[0228] According to a seventh aspect, a probe device is provided for use in non-destructive evaluation of a subject, the probe device comprising or in the form of a roller probe, and the probe device comprising a transducer assembly comprising or in the form of a transmit-receive-longitudinal (TRL) configuration.

[0229] The probe device may include a transducer configuration. The transducer configuration may be configured and / or operable to direct an ultrasonic beam toward the subject. The transducer configuration may include one or more transducers.

[0230] The probe device may include a compliant element. The compliant element may be configured to engage with the subject. The compliant element may include or be in the form of a rolling element. The compliant element may include or be in the form of a tire, wheel, etc. For example, as described above, the probe device may include or be in the form of a roller probe.

[0231] The probe device may include one or more intermediate members. The one or more intermediate members may be interposed between the transducer configuration and the compliant element.

[0232] The transducer configuration and the one or more intermediate members may together form a transducer assembly for the probe device.

[0233] As described above, the transducer assembly may have or be configured with a transmit / receive split longitudinal wave (TRL) configuration.

[0234] At least one of the aforementioned intermediate members may be inclined.

[0235] During use, each of the plurality of intermediate members may be inclined so that the ultrasonic beam transmitted by the plurality of transducers in the transducer configuration can be focused at the focal point.

[0236] According to the eighth aspect, a probe device is provided for use in non-destructive evaluation of a subject, the probe device comprising a transducer configuration configured and / or operable to direct an ultrasonic beam toward the subject, wherein the probe device comprises or is configured to be a roller probe, and the transducer configuration comprises or is configured to be a matrix array.

[0237] The transducer configuration may comprise one or more transducers. As described above, the transducer configuration may comprise or take the form of a matrix array.

[0238] The probe device may include a compliant element. The compliant element may be configured to engage with the subject. The compliant element may include or be in the form of a rolling element. The compliant element may include or be in the form of a tire, wheel, etc. For example, as described above, the probe device may include or be in the form of a roller probe.

[0239] The probe device may include an intermediate member. The intermediate member may be interposed between the transducer configuration and the compliant element.

[0240] According to the ninth aspect, a method for non-destructive evaluation of a subject is provided, the subject comprising or in the form of a non-welded structure, the method comprising the steps of: radiating ultrasonic waves to the subject and receiving ultrasonic waves returning from the subject to obtain a plurality of signal sets, including a first signal set and a second signal set; and processing the first signal set and the second signal set to provide evaluation data relating to the subject, wherein the first signal set comprises a first sequence of first data elements over a first period, each of the first data elements comprising a first variable value for a variable and a first time value for the first variable value, the first period comprising a first time sub-period; the second signal set comprises a second sequence of second data elements over a second period, each of the second data elements comprising a second variable value for the variable and the second The first and second time subperiods include a second time value for a variable value, the second period includes a second time subperiod, the first and second time subperiods include the same time value, the processing of the first and second signal sets determines a modified signal set that contributes to the evaluation data, wherein the modified signal set includes a modified time subperiod that includes the same time value as the first and second time subperiods, and with respect to the time value, if the first and second variable values ​​are in a predetermined relationship with respect to that time value, the modified signal set includes an expression of the first variable value and an expression of the second variable value with respect to that time value, and / or, if the first and second variable values ​​are not in a predetermined relationship with respect to that time value, the modified signal set includes an expression of the first variable value or an expression of the second variable value with respect to that time value.

[0241] The method may include a preliminary step of providing a probe device and positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject. The method may also include positioning the probe device near the subject. The method may also include positioning the probe device in contact with the subject. The method may also include positioning the probe device adjacent to the subject without contact with the subject.

[0242] The subject can take on various different forms.

[0243] For example, the subject may include or be in the form of an object constructed using additive manufacturing technology. In particular, the subject may include or be in the form of an object constructed using metal additive manufacturing such as (but not limited to) wire arc additive manufacturing (WAAM).

[0244] Metal additive manufacturing is a method of metal manufacturing that involves continuously adding multiple layers to produce a metal object. Metal additive manufacturing is different from subtractive methods, which form metal parts by removing material or by shaping material, such as by machining, milling, or forming.

[0245] Therefore, the method can be defined as a method for non-destructive evaluation of objects constructed using additive manufacturing techniques. Therefore, the method can be further defined as a method for non-destructive evaluation of objects constructed using metal additive manufacturing techniques such as wire arc additive manufacturing (WAAM), but is not limited to this definition.

[0246] Alternatively, the subject may comprise or be in the form of an object constructed from a composite material.

[0247] Therefore, the method can be defined as a method for use in the non-destructive evaluation of objects constructed from composite materials.

[0248] Alternatively, the subject may include or be in the form of a human or animal body.

[0249] Therefore, a method may be defined as a method for use in the non-invasive assessment of the human or animal body. A method may be further defined as a method for use in the therapeutic or non-therapeutic non-invasive assessment of the human or animal body.

[0250] The first variable value may be, for example, a representation of the amplitude at a given time value, and in particular, the amplitude of a set of rectified signals.

[0251] The second variable value could be, for example, a representation of the amplitude at a given time value, and in particular, the amplitude of a set of rectified signals.

[0252] The first period, the second period, and / or one or more further periods may have the same duration. The first period, the second period, and / or one or more further periods may have the same duration ±25%. The first period, the second period, and one or more further periods may be the duration of the receiver signal of an ultrasonic beam or wave. The first time sub-period and / or the second time sub-period and / or one or more further sub-time periods may be individual time values. The first time sub-period and / or the second time sub-period and / or one or more further sub-time periods may be a small collection of individual time values.

[0253] The first period may be considered as a plurality of different or partially overlapping first time subperiods. The second period may be considered as a plurality of different or partially overlapping second time subperiods. Further periods may be considered as a plurality of different or partially overlapping further time subperiods. The plurality of time subperiods may be paired with each other if they are for the same time value. The modified signal set may be organized from the consideration of the plurality of time subperiods in accordance with this method.

[0254] The method may specify that in the corrected signal set, the representation of the first variable value for the time value and the representation of the second variable value for the time value may be the average of the first variable value and the second variable value. The method may also specify that in the corrected signal set, the representation of the first variable value for the time value and / or the representation of the second variable value for the time value may be the average of all variable values ​​in a predetermined relationship, along with further variable values.

[0255] The method may specify that the first variable value and the second variable value are in a predetermined relationship with respect to each other when the first variable value and the second variable value are within a predetermined threshold. The properties and / or defining function and / or value of the predetermined threshold may be variable. The threshold may vary so as to increase particularly when the system gain increases and / or when the noise in the signal set increases. The threshold may vary so as to increase particularly when the interference level in the signal set increases. The properties and / or defining function and / or value of the threshold may be determined in the calibration method.

[0256] The method may specify that the first and second variable values ​​are not in a predetermined relationship with each other if the first and second variable values ​​are outside a further predetermined threshold, potentially outside the same threshold. The nature and / or defining function and / or value of the predetermined threshold may be variable. The further predetermined threshold may vary to increase particularly when the system gain increases and / or when the noise in the signal set increases. The further predetermined threshold may vary to increase particularly when the interference level in the signal set increases.

[0257] The method may further specify that if the first variable value and the second variable value are not in a predetermined relationship with respect to each other, one of the included expressions selected from the first and second is an expression having a lower variable value with respect to the time value. The method may further specify that if the variable value and the variable value being compared are not in a predetermined relationship with respect to each other, one of the included expressions is an expression having a lower variable value with respect to the time value. The lower variable value may be a lower variable value in absolute terms.

[0258] The predetermined threshold may be determined relative to the amplitudes for the first variable value and the second variable value.

[0259] The amplitude may be a predetermined amplitude value. The amplitude may be relative to an expected amplitude value, for example, an expected noise amplitude. The amplitude may be defined as a predetermined percentage or multiple of the expected noise amplitude.

[0260] The amplitude may be an observed amplitude. The amplitude may also be related to the maximum amplitude observed in a set of variable values ​​that are considered to have no interference.

[0261] The amplitude may be related to the minimum value observed over a given time or time period across all the variable values ​​under consideration, for example, over the first variable value, the second variable value and one or more further variable values. The amplitude may be the minimum value plus a coefficient. This amplitude may be considered an interference-free threshold.

[0262] The threshold may be the difference between the observed value and the analyzed value. The observed value and the analyzed value may be amplitudes. The analyzed value may be obtained from the minimum value observed over a predetermined time or period across all the variable values ​​under consideration, for example, over the first variable value, the second variable value and one or more further variable values. The analyzed value may be obtained by adding a coefficient to the minimum value.

[0263] The method may further include obtaining one or more additional signal sets as part of the plurality of signal sets.

[0264] The method may further include processing one or more of the further signal sets in order to provide evaluation data.

[0265] The method may further include one or more of the further signal sets comprising a further sequence of further data elements, each of which comprises a further sequence of further data elements over a further time period, each of which comprises a further variable value for the variable and a further time value for the further variable value, and each of which comprises a further time sub-period.

[0266] The method may further include the fact that one of the further time subperiods includes the same time value as at least one of the first time subperiod and / or the second time subperiod.

[0267] The method may further include determining a modified signal set in which one or more of the processing of the further signal sets contributes to the evaluation data.

[0268] The method may further include the correction signal set extending over a further time subperiod and a correction time subperiod that includes the same time value as one or both of the first time subperiod and the second time subperiod.

[0269] The method may further include, if the correction signal set has a predetermined relationship with respect to the time value, a representation of the first variable value, a representation of the second variable value, and a representation of the further variable value for the time value.

[0270] The method may, alternatively or additionally, include, if the set of corrected signals does not have a predetermined relationship with respect to the time value, a representation of the first variable value, a representation of the second variable value, or one of the further representations of the variable value.

[0271] The method may also, alternatively or additionally, further include, with respect to a time value, two of the following: a representation of a first variable value for the time value, a representation of a second variable value for the time value, and the further representation of the variable value for the time value, provided that the two variable values ​​are in a predetermined relationship with respect to each other.

[0272] The method may also, alternatively or additionally, further include, with respect to a time value, only one of the following: namely, a representation of a first variable value for the time value, a representation of a second variable value for the time value, and the further representation of the variable value for the time value, wherein the variable values ​​are not in a predetermined relationship with respect to each other.

[0273] The method may further specify that the correction signal set is comprised of a plurality of correction time subperiods, each of which contains the same time value as the first time subperiod and / or the second time subperiod and / or one or more further time subperiods.

[0274] According to a tenth aspect, a method for non-destructive evaluation of a subject is provided, wherein the subject comprises or is in the form of a non-welded structure, and the method includes the step of performing the evaluation, wherein the subject is provided at a temperature above ambient temperature by heating during the evaluation, the step of performing the evaluation includes emitting ultrasound into the volume of the subject, receiving at least a portion of the ultrasound returning from the subject and thereby obtaining a plurality of signal sets, and processing one or more of the plurality of signal sets to provide evaluation data relating to the subject, wherein the processing includes a correction for the temperature of the subject within the volume at the heated temperature. The method may include a preliminary step of providing a probe device and positioning the probe device relative to the subject so that the probe device can emit ultrasound into the subject and receive ultrasound returning from the subject. The method may include positioning the probe device in the vicinity of the subject. The method may include positioning the probe device in contact with the subject. The method may include positioning the probe device adjacent to the subject without contact with the subject. The subject can take on various different forms.

[0275] For example, the subject may include or be in the form of an object constructed using additive manufacturing technology. In particular, the subject may include or be in the form of an object constructed using metal additive manufacturing such as wire arc additive manufacturing (WAAM), although this is not limited to the subject.

[0276] Metal additive manufacturing is a method of metal manufacturing that involves continuously adding multiple layers to produce a metal object. Metal additive manufacturing is different from subtractive counter-methods that form metal parts by removing material, or by shaping material, for example, by machining, milling, or forming.

[0277] Therefore, the method may be defined as a method for non-destructive evaluation of objects constructed using additive manufacturing techniques. Therefore, the method may further be defined as a method for non-destructive evaluation of objects constructed using metal additive manufacturing techniques such as wire arc additive manufacturing (WAAM), but is not limited to this.

[0278] Alternatively, the subject may comprise or be in the form of an object constructed from a composite material.

[0279] Therefore, the method may be defined as a method for use in the non-destructive evaluation of objects constructed from composite materials. The method may include a heating temperature that is uniform throughout the entire specimen and / or a temperature distribution in the specimen and / or probe device, such as a temperature gradient.

[0280] The process includes correction of the temperature distribution within the volume of the sample at the heating temperature, such as a temperature gradient.

[0281] The method may specify that the correction includes correcting at least a portion of the path of ultrasound passing through the probe device and / or the volume of the subject to provide a corrected path.

[0282] The method may specify that the portion of the ultrasound has path characteristics in one or more elements through which the path passes. The method may specify that the portion of the ultrasound in the probe device has path characteristics in one or more medium elements. The method may specify that the portion of the ultrasound in the substrate has path characteristics in one or more substrate elements. The method may specify that the portion of the ultrasound in the subject has path characteristics in one or more object elements. The method may specify that the portion of the ultrasound in the interface between the probe device and the substrate has path characteristics in one or more interface elements.

[0283] The ultrasound may have path characteristics in each of the multiple elements, for example, in each element adjacent to the preceding element and the succeeding element, respectively. The ultrasound may have path characteristics in each of one or more medium elements. The ultrasound may have path characteristics in each of one or more interface elements. The ultrasound may have path characteristics in each of one or more substrate elements. The ultrasound may have path characteristics in each of the one or more object elements.

[0284] The ultrasound may have path characteristics in each of one or more medium elements, and then in each of one or more base material elements. The ultrasound may have path characteristics in each of one or more interface elements, for example, after the medium elements and / or before the base material elements. The ultrasound may have path characteristics in each of one or more welding elements, for example, after the base material elements.

[0285] Ultrasound may further have path characteristics in each of one or more substrate elements, for example, in the return path, and thereafter have path characteristics in each of one or more medium elements. Ultrasound may have path characteristics in each of one or more object elements, for example, it may have path characteristics before the substrate element. Ultrasound may have path characteristics in each of one or more interface elements, for example, it may have path characteristics after the substrate element and / or before the medium element.

[0286] The method may specify that a portion of the ultrasound has path characteristics in a probe device element, e.g., a medium element, and / or at an interface, e.g., an interface element, before it enters a first element of the substrate, e.g., a first substrate element. The method may specify that the first element has a temperature distribution over the volume of the substrate and / or weld, e.g., a temperature gradient, and that a temperature-compensated path characteristic is determined for a portion of the ultrasound in the first element, and that the temperature-compensated path characteristic is based on a temperature change between a welding inspection device element, e.g., a medium element and / or an interface element, and a first element of the substrate, e.g., a first substrate element.

[0287] The change in path characteristics may be calculated according to Snell's law of refraction.

[0288] The method may further specify that a portion of the ultrasound has path characteristics in a first element of the substrate, for example, a first substrate element, before entering a second element of the substrate, for example, a second substrate element. The method may further specify that the first element has a temperature distribution over the volume of the substrate and / or weld, for example, a temperature gradient, and the second element has a temperature distribution over the volume of the substrate and / or weld, for example, a temperature gradient, and that a temperature-compensated path characteristic is determined for a portion of the ultrasound in the second element, for example, a second substrate element, and that the temperature-compensated path characteristic is based on a temperature change between the first element and the second element, for example, a temperature change between the first substrate element and the second substrate element.

[0289] The method may further specify that a portion of the ultrasound has path characteristics in a first further element of the substrate, e.g., a first further substrate element, and then the portion of the ultrasound enters a second further element of the substrate, e.g., a second further substrate element. The method may further specify that the first further element has a temperature distribution over the volume of the substrate and / or subject, e.g., temperature within a temperature gradient, and the second further element has a temperature distribution over the volume of the substrate and / or subject, e.g., temperature within a temperature gradient, and that a temperature-compensated path characteristic is determined for the portion of the ultrasound in the second further element, e.g., a second further substrate element, and that the temperature-compensated path characteristic is based on a temperature change between the first further element and the second further element, e.g., a temperature change between the first further substrate element and the second further substrate element.

[0290] The method may specify that the temperature compensation path characteristics are determined for each element through which a portion of the ultrasound passes in the probe device and / or substrate and / or specimen, for example, for each element through which the ultrasound passes in the welding inspection device and / or substrate and / or specimen.

[0291] The method may specify that the temperature change is expressed as a change in the speed of sound between the speed of sound in one element and the speed of sound in the next element.

[0292] The method may specify that multiple different portions of the ultrasonic waves in the welding inspection device and / or the substrate and / or the specimen are corrected to provide a corrected path, for example, that the correction is applied to the entire path through the welding inspection device and / or the substrate and / or the specimen.

[0293] The method may provide multiple correction paths, for example, all paths through the probe device and / or substrate and / or subject, and / or all paths through the return path. The method may provide at least five correction paths, possibly at least 15 correction paths, potentially at least 25 correction paths, and optionally at least 40 correction paths, or for example, 64 correction paths.

[0294] The correction path may be provided for the path of each beam of ultrasound emitted by the transducer, for example, a 64-element phased array.

[0295] The method may specify that a region of interest is selected, which lies within the volume of the substrate and subject through which the ultrasound passes, and the region of interest is subdivided into locations, e.g., pixels. The method may apply signal correction to locations, e.g., pixels. The method may apply signal correction to each location within the region of interest, e.g., each pixel. It may also be applied to the beam path to locations, e.g., pixels, and / or the return beam path.

[0296] The method may specify that signal correction is determined according to a relationship between a position, for example, a pixel, and at least one, preferably at least one pair, correction paths. The relationship may be a geometric relationship. The relationship may be a weighted correction based on the geometric position relative to one or more correction paths.

[0297] The method may specify that the signal correction is determined according to the relationship between a position, such as a pixel, and at least one, preferably at least one of at least a pair of positions on at least one, preferably at least a pair of correction paths. The relationship may be a geometric relationship. The relationship may be a weighted correction based on the relative geometric position, such as distance, between a position and at least one, preferably at least one of at least a pair of positions on at least one, preferably at least a pair of correction paths.

[0298] The method may include signal correction for one or more positions, such as pixels, through which the correction path of the emitted ultrasonic beam passes. The signal correction may be mainly or exclusively based on the correction path of the emitted ultrasonic beam passing through the position, such as a pixel. The signal correction may be based on a relationship that is a weighted correction based on the relative geometric position, such as distance, between the position and at least one, preferably at least one of at least a pair of positions on at least one, preferably at least a pair of correction paths, and the signal correction may be mainly or exclusively based on the correction path of the emitted ultrasonic beam passing through the position, such as a pixel.

[0299] The method may include signal correction for one or more positions, such as pixels, through which the correction path of the emitted ultrasonic beam does not pass. The method may include signal correction for positions, such as pixels, through which the correction path of the emitted beam does not pass, based on the correction calculated or observed for the positions through which the correction path of the emitted beam passes. The signal correction may be based on the positions calculated or observed for a plurality of positions, such as four positions, through which the emitted beam has passed.

[0300] The signal correction may be based on the positions calculated or observed for a plurality of positions on the first emitted beam and a plurality of positions on the second emitted beam. The first emitted beam and the second emitted beam may be adjacent beams within a beam set. The first beam may be on one side of the position requiring signal correction, and the second beam may be on the other side of the position requiring signal correction.

[0301] The signal correction for a position may be a weighted combination of signal corrections for one or more other positions, for example, one or more other positions through which the radiated beam has passed. The weighted combination may be based on four positions. The weighted combination may be based on two positions on one beam and two positions on another beam.

[0302] The signal correction for position may be weighted according to the proportion of the distance occupied by the position in question to the distance between the position on the first beam and the position on the second beam. The signal correction for position may also be weighted according to the ratio of the distance the position is from the position on the first beam to the distance the position is from the position on the second beam, for example, by weighting the corrections from these positions. The distances are equidistant from the transducer and may be considered along the arc passing through the first beam, the position to be corrected, and the second beam.

[0303] The signal correction for position may be weighted according to the proportion of the distance occupied by the position to the distance between a first position on the first beam and a second position on the first beam. The signal correction for position may also be weighted according to the ratio of the distance from the position to the first position on the first beam to the distance from the position to the second position on the first beam, for example, by weighting corrections from these positions. The distance may be considered along the first beam. Distance values ​​for each position, such as a pixel, within the region of interest or within the substrate may be calculated and stored in advance.

[0304] The speed of sound at each position, such as a pixel, within the region of interest or within the substrate may be calculated.

[0305] The beam paths through each boundary between positions, such as pixels, within the region of interest or within the substrate may be calculated, for example, according to Snell's law of refraction.

[0306] Temperature may be mapped to each location, such as a pixel, within the region of interest or within the substrate. Temperature contour lines may be assigned to the region of interest or the substrate, for example, perpendicular to the surface of the substrate.

[0307] The method may include determining the travel time to pass through each location, which may be determined, for example, by the distance and speed in the zone. The method may define the net travel time as the sum of the travel times to pass through all locations along the path.

[0308] The method may further specify that the result set includes one or more measured indices of a substrate and / or object groove and / or object shape, wherein the method further includes comparing the measured indices of shape with indices of a modeled shape, wherein the comparison of the measured indices of shape with the indices of the modeled shape establishes that the measured indices of shape fit well with respect to the indices of the modeled shape, and accepts imaging of the region of interest.

[0309] The method may further specify that the result set includes one or more measured indices for the shape of the substrate and / or object grooves and / or welds, wherein the method further includes comparing the measured indices for the shape with indices for a modeled shape, wherein if the comparison of the measured indices for the shape with indices for the modeled shape establishes that the measured indices for the shape are inadequately suited to the indices for the modeled shape, the temperature distribution used in the correction for the temperature distribution within the volume of the substrate and / or welds at heating temperatures above ambient temperature is predetermined.

[0310] The method may be defined to include providing a thermal model and using the thermal model to generate a modeled temperature distribution location for at least a portion of a substrate at a temperature above ambient temperature, wherein the portion of the substrate includes the volume. The method may be defined to include measuring the temperature at a plurality of locations on the substrate at a temperature above ambient temperature to obtain measured temperature distribution locations, and the method may further include comparing the measured temperature distribution locations with the modeled temperature distribution locations. The method may further include revising the thermal model and / or the modeled temperature distribution locations and then recomparing them if comparing the measured temperature distribution locations with the modeled temperature distribution locations establishes that the modeled temperature distribution is an inadequate fit to the measured temperature distribution.

[0311] The method may further include, if comparing the measured temperature distribution location with the modeled temperature distribution location establishes that the modeled temperature distribution fits well with the measured temperature distribution, calculating the properties of the ultrasound emitted while passing through at least a portion of the substrate and / or subject.

[0312] According to an eleventh aspect, a method for non-destructive evaluation of a subject is provided, wherein the subject comprises or is in the form of a non-welded structure, the method comprising providing an ultrasonic probe, the ultrasonic probe comprising an axial element, an ultrasonic emitting transducer attached to the axial element, two or more support elements rotatably mounted with respect to the axial element, and a compliant element, wherein the compliant element is attached to the two or more support elements and the compliant element provides a continuous surface in at least one direction, wherein the two or more support elements and the compliant element define at least a portion of an internal volume for the probe, the transducer is provided within the internal volume, the probe further comprises an inlet for a coolant into the internal volume and an outlet for a coolant out of the internal volume, the method further provides the steps of positioning at least a portion of the compliant element in contact with the subject, and passing ultrasonic waves from the transducer to the subject and detecting reflected ultrasonic waves from a substrate, wherein during the passage of the ultrasonic waves, a coolant is supplied to the internal volume through the coolant inlet and the coolant is removed from the internal volume.

[0313] The method may include a preliminary step of providing a probe device and positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject. The method may also include positioning the probe device in the vicinity of the subject. The method may also include positioning the probe device in contact with the subject. The method may also include positioning the probe device adjacent to the subject without contacting the subject.

[0314] The subject can take on various different forms.

[0315] For example, the subject may include or be in the form of an object constructed using additive manufacturing technology. In particular, the subject may include or be in the form of an object constructed using metal additive manufacturing such as wire arc additive manufacturing (WAAM), although this is not limited to the subject.

[0316] Metal additive manufacturing is a method of metal manufacturing that involves successively adding a number of layers to manufacture a metal object. Metal additive manufacturing is a different method from subtractive methods that form metal parts by removing material or shape the material by, for example, machining, milling or forming.

[0317] Thus, the method can be defined as a method for use in non-destructive evaluation of an object constructed using additive manufacturing techniques. Thus, the method can further be defined as a method for use in non-destructive evaluation of an object constructed using a metal additive manufacturing technique such as, but not limited to, wire arc additive manufacturing (WAAM).

[0318] Alternatively, the subject may comprise or be in the form of an object constructed from a composite material.

[0319] Thus, the method can be defined as a method for use in non-destructive evaluation of an object constructed from a composite material. The method may specify that the temperature of the subject at the location where the portion of the compliant element contacts is at least 250°C. The method may specify that the temperature of the subject at the location where the portion of the compliant element contacts is at least 300°C.

[0320] The method may include, for example, rolling the probe over the subject such that different portions of the compliant element contact the subject at different locations on the subject.

[0321] The method may include pumping a coolant into and / or out of the probe device.

[0322] The method may include cooling the coolant outside the probe device. The method may include cooling the coolant using a heat exchanger.

[0323] The method may include returning the coolant to the internal volume a plurality of times.

[0324] In another embodiment, a computer program product is provided which, when processed by a suitable processing system, constitutes the processing system and implements one or more of the embodiments described above.

[0325] The aforementioned computer program product may be provided on or contained within a carrier medium. The carrier medium may be temporary or non-temporary. The carrier medium may be tangible or intangible. The carrier medium may contain signals such as electromagnetic signals or electronic signals. The carrier medium may include physical media such as disks, memory cards, memory, and / or similar devices.

[0326] In another embodiment, a carrier medium is provided, the carrier medium includes a signal, and the signal is processed by a suitable processing system, causing the processing system to implement one or more of the embodiments described above.

[0327] As will be readily apparent to those skilled in the art, some embodiments may implement certain functions by computer programs having executable computer-readable instructions for performing the methods of the embodiments. The functions of the computer programs may be implemented in hardware, for example, by a CPU, or by one or more ASICs (application-specific integrated circuits), or by one or more FPGAs (field-programmable gate arrays), or by a combination of hardware and software.

[0328] While specific devices are described herein, in alternative embodiments, one or more functions of these devices may be provided by a single unit, processing resource, or other component, or a function provided by a single unit may be provided by a combination of two or more units or other components. For example, one or more functions of a processing system may be performed by a single processing device such as a personal computer, or one or more functions, or each function, may be performed in a distributed manner by multiple processing devices that are locally connected or remotely distributed.

[0329] The invention is defined by the appended claims. However, for the purposes of this disclosure, it will be understood that any of the features defined above or described below may be used individually or in combination. For example, a feature described above in relation to one of the above embodiments or a feature described below in relation to the detailed description may be used in any other embodiment or combined to form a new embodiment. [Brief explanation of the drawing]

[0330] These and other embodiments are described below, by reference only to the attached drawings. [Figure 1] This is a schematic diagram of a probe device used for non-destructive evaluation of a subject W, and the probe device is generally indicated as 10. [Figure 2] This is a schematic diagram of the probe device shown in Figure 1, with the compliant elements removed. [Figure 3] Figure 1 is a cross-sectional view of the probe device shown. [Figure 4] Figure 1 is a schematic diagram of the transducer configuration and intermediate components of the probe device shown. [Figure 5A] Surface treatment is shown. [Figure 5B] Surface treatment is shown. [Figure 5C] Surface treatment is shown. [Figure 5D] Surface treatment is shown. [Figure 6]Figure 1 is a schematic diagram of a system used for non-destructive evaluation of a test subject, equipped with the probe device shown. [Figure 7] This is a schematic diagram of an alternative probe device. [Figure 8] This is a schematic diagram of a probe device used for non-destructive evaluation of the subject W, and the probe device is generally indicated as 110. [Figure 9] Figure 8 is a schematic diagram of the probe device with compliance elements removed. [Figure 10] Figure 8 is a cross-sectional view of the probe device shown. [Figure 11] Figure 8 is a schematic diagram of the transducer configuration and intermediate components of the probe device shown. [Figure 12A] Surface treatment is shown. [Figure 12B] Surface treatment is shown. [Figure 12C] Surface treatment is shown. [Figure 12D] Surface treatment is shown. [Figure 13] Figure 8 is a schematic diagram of a system used for non-destructive evaluation of a test subject, equipped with the probe device shown. [Figure 14] This graph shows error propagation due to angular deviation. [Figure 15] This graph shows a parametric analysis of beam angle errors for various angles of the compliant element, relative to the intended ultrasonic beam angle. [Figure 16] This is a schematic diagram of an alternative probe device. [Figure 17] This is a schematic diagram of the transducer configuration and intermediate components of an alternative probe device. [Figure 18] This is a cross-sectional view of the transducer configuration and intermediate members of an alternative probe device. [Figure 19] This is a perspective view of the transducer configuration of an alternative probe device. [Figure 20] This document describes a method for non-destructive evaluation of the subject. [Figure 21] An example of the method shown in Figure 20 is presented. [Figure 22]Another example of the method shown in Figure 20 is presented. [Figure 23] Another example of the method shown in Figure 20 is presented. [Figure 24] This describes another method for non-destructive evaluation of the subject. [Figure 25] An example of the method shown in Figure 24 is presented. [Figure 26] Another example of the method shown in Figure 24 is presented. [Figure 27] This describes another method for non-destructive evaluation of the subject. [Figure 28] An example of the method shown in Figure 27 is presented. [Figure 29] Another example of the method shown in Figure 27 is presented. [Figure 30] Figures 27 to 29 show the probe device used to implement the method. [Figure 31] Figures 27 to 29 show the probe device used to implement the method. [Figure 32] Figures 27 to 29 show the probe device used to implement the method. [Figure 33] Figures 27 to 29 show the probe device used to implement the method. [Figure 34] Figures 27 to 29 show the probe device used to implement the method. [Figure 35] Figures 27 to 29 show the probe device used to implement the method. [Figure 36] Figures 27 to 29 show the probe device used to implement the method. [Figure 37] Figures 27 to 29 show the probe device used to implement the method. [Figure 38] Figures 27 to 29 show the probe device used to implement the method. [Figure 39] Figures 27 to 29 show the probe device used to implement the method. [Figure 40] Figures 27 to 29 show the probe device used to implement the method. [Modes for carrying out the invention]

[0331] Referring first to Figures 1, 2, and 3 of the attached drawings, schematic and cross-sectional views, respectively, of a probe device generally designated as 10, used for non-destructive evaluation of the subject W.

[0332] As shown in the figure, the probe device 10 includes a transducer configuration configured and / or operable to direct an ultrasonic beam U toward a subject W, the transducer configuration generally shown as 12, a compliant element configured to engage with the subject W, the compliant element generally shown as 14, and an intermediate member interposed between the transducer configuration 12 and the compliant element 14, the intermediate member generally shown as 16.

[0333] As best shown in Figure 3, the intermediate member 16 and the compliant element 14 are positioned to define an interface 18 between them, and as further described below, the intermediate member 16 and the compliant element 14 are configured and / or operable to hold the fluid 20 located at the interface 18 between the intermediate member 16 and the compliant element 14.

[0334] During use, the probe device 10 is placed on the subject W, and the compliant element 14 receives a force that biases the compliant element 14 to engage with or enhance the engagement with the subject W. The transducer configuration 12 is configured and / or operable to direct an ultrasonic beam U toward the subject W, and one or more characteristics of the reflected beam R are detected by the transducer configuration 12 and / or another detection configuration to determine the characteristics, state, health and / or behavior of the subject W. The probe device 10 includes an inlet configuration generally indicated as 11, which includes one or more inlets 13. The probe device 10 also includes an outlet configuration generally indicated as 15, which includes one or more outlets 17. The inlet configuration 11 and the outlet configuration 15 are coupled and / or operablely associated with a fluid configuration generally indicated as 19. The fluid configuration 19 includes a cooling configuration 21. The probe device 10 includes a valve configuration generally indicated as 23. As described above, the fluid 20 is supplied to the internal volume 30 of the compliant element 14 by the fluid configuration 19 via the inlet configuration 11. The fluid 20 is positioned within the probe device 10, including the fluid 20 at the interface 18 between the intermediate member 16 and the compliant element 14, and the fluid 20 acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element 14 and to the subject W. The fluid 20 is cooled by the cooling configuration 21 before being supplied to the internal volume 30. The fluid 20, whose temperature has risen through the use of the probe device 10, is then removed from the internal volume 30 of the compliant element 14 by the fluid configuration 19 via the outlet configuration 15. While the hot fluid 20 is being removed from the internal volume 30, the fluid configuration 19 simultaneously supplies cooled fluid 20 to the internal volume 30 via the cooling configuration 21 to replace the removed hot fluid 20. The cooling configuration 21 then cools the removed high-temperature fluid 20, and the cooled fluid 20 is resupplied to the internal volume 30 of the compliant element 14 via the inlet configuration 11. In this probe device 10, one or both of the intermediate member 16 and the compliant element 14 are configured and / or operable to hold the fluid 20 located at the interface 18 between the intermediate member 16 and the compliant element 14.

[0335] The probe device 10 offers many advantages over conventional devices.

[0336] For example, the probe device 10 eliminates or at least reduces the possibility of fluid 20 being discharged from the interface 18 between the intermediate member 16 and the compliant element 14 when the probe device 10 is in use. This is because, in particular, but not limited to, the load force that biases the intermediate member 16 to engage with the compliant element 14 would push the fluid 20 out of the interface 18. This maintains the cooling effect at the interface 18, and as a result facilitates the use of the probe device 10 at higher temperatures and / or the prolonged effective use of the probe device 10 at a given temperature.

[0337] Furthermore, by eliminating or at least reducing the possibility of fluid 20 being discharged from the interface 18 between the intermediate member 12 and the compliant element 14, effective transmission of the ultrasonic beam U from the transducer configuration 12 to the compliant element 14 and further to the subject W is maintained. This makes it possible to apply a wider range and / or variable load force to the device 10. For example, a larger load force may be applied to the device 10 to improve tracking of the subject W, and even in this case, the transmission capability of the ultrasonic beam U between the intermediate member 12 and the compliant element 14, and to the subject W, is not adversely affected. Alternatively, since the possibility of fluid 20 being discharged from the interface 18 is eliminated or at least reduced, a smaller load force may be applied to the device 10, and the fluid 20 is retained within the interface 18, ensuring effective transmission of the ultrasonic beam U compared to conventional devices, without relying on conventional devices to apply high load forces to the device 10.

[0338] The probe device 10 is configured and / or operable to facilitate dry couprant testing of the subject W, i.e., no liquid couprant is used between the probe device 10 and the subject W.

[0339] Advantageously, dry couprant testing allows for faster evaluation of the subject W and / or eliminates or at least reduces the risk of liquid couprant contaminating the subject W and / or the environment.

[0340] However, in some embodiments, it will be understood that the probe device 10 uses a liquid couplant, such as a gel.

[0341] The probe device 10 is particularly applicable in the field of welding inspection, for example, but not limited to, facilitating high-temperature compliant welding inspection not only on welds after and / or during the welding process, but also during and / or immediately after the welding process, thereby enabling better control of the welding process to ensure welding quality. This advantageously eliminates or at least reduces the need for rework, resulting in benefits in terms of improved schedule certainty and / or reduced manufacturing lead time.

[0342] Alternatively, the probe device 10 is particularly applicable to the inspection of objects constructed using additive manufacturing technology.

[0343] As described above, the probe device 10 includes a transducer configuration 12 that is configured and / or operable to direct an ultrasonic beam U toward the subject W.

[0344] In the illustrated embodiment, the transducer configuration 12 comprises or is configured to include a transducer array 22, and in particular, the transducer configuration 12 comprises or is configured to include a phased array ultrasonic transducer (PAUT) configuration.

[0345] The transducer configuration 12 is configured and / or operable to transmit and / or receive an ultrasonic beam U.

[0346] The transducer configuration 12 is coupled to and / or operably associated with the ultrasonic driver device 44.

[0347] During use, the ultrasonic beam U is focused using a time delay to generate constitutive interference at the wavefront of concern. Such interference allows energy to be focused at any depth and angle within the object W. To facilitate the generation of such constitutive interference, the transducer configuration 12 includes transducers that transmit and / or receive independently at different times.

[0348] Alternatively or additionally, as described above, the ultrasonic driver device 44 transmits high-voltage electrical pulses, thereby causing each of the one or more transmitters to transmit an ultrasonic beam U at a separate interval from each other transmitter, and the reflection from each transmitted ultrasonic beam U is received by one or more receivers. When multiple receivers receive the reflected ultrasonic beam U, the ultrasonic driver device 44 receives the corresponding signal and records the signal. This recorded data can then be used to perform advanced reconstruction to generate constitutive interference in the wavefront of concern.

[0349] As described above, the probe device 10 includes an intermediate member 16 interposed between the transducer configuration 12 and the compliant element 14.

[0350] In the illustrated embodiment, the intermediate member 16 includes or has a wedge portion 24.

[0351] The intermediate member 16 is constructed partially or entirely from a plastic material, the plastic material comprising or in the form of a thermoplastic material. In the illustrated embodiment, the plastic material comprises or in the form of polyetherimide, for example, Ultem(R). Alternatively or additionally, the plastic material may comprise or in the form of polyimide, for example, Vespel(R). The plastic material may comprise or in the form of polyamideimide, for example, Duratron(R).

[0352] Advantageously, the intermediate member 16 provides high strength and high temperature capability, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material parts during and / or immediately after the manufacturing process.

[0353] As shown in Figure 4, the transducer configuration 12 and the intermediate member 16 together form the transducer assembly of the probe device 10, which is generally shown as 26.

[0354] At least one of the transducer assembly 26 and the compliant element 14 is configured and / or operable to hold the fluid 20 located at the interface 18 between the intermediate member 16 and the compliant element 14.

[0355] As described above, the probe device 10 includes a compliant element 14 configured to be positioned between the intermediate member 16 and the subject W.

[0356] The compliant element 14 is constructed in part or in whole from an elastomer material, which comprises or takes the form of a silicone rubber material. In the illustrated embodiment, the compliant element 14 is constructed in part or in whole from high-temperature silicone rubber.

[0357] Advantageously, the compliant element 14 can conform to the shape of the specimen W and provides high strength and high temperature capability, thereby facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after a welding process, metal objects during and / or immediately after a metal additive manufacturing process, or composite material parts during and / or immediately after a manufacturing process.

[0358] The compliant element 14 comprises or is in the form of a cylindrical or substantially cylindrical element.

[0359] The probe device 10 is configured such that the compliant element 14 moves relative to the intermediate member 16. For example, the probe device 10 is configured such that the compliant element 14 rotates around the intermediate member 16 and / or the transducer configuration 12. In the illustrated embodiment, the compliant element 14 includes or is configured to include a rolling element 28, and the compliant element 14 includes or is configured to include a tire, wheel, etc.

[0360] The probe device 10 is configured such that the compliant element 14 moves axially relative to the intermediate member 16.

[0361] As described above, the compliant element 14 defines at least partially the internal volume 30. The internal volume 30 comprises or is in the form of a chamber, and the transducer assembly 26 is located within the internal volume 30.

[0362] The probe device 10 comprises a support configuration generally referred to as 32. The support configuration 32 comprises or is configured to include a mandrel 34. When in use, the mandrel 34 forms the axle of the probe device 10.

[0363] The transducer assembly 26 is supported by the mandrel 34, for example, and is attached to the mandrel 34, and the transducer assembly is fixedly coupled to the mandrel 34, for example, and is fixedly attached to the mandrel 34.

[0364] The compliant element 14 is movably supported by a mandrel 34, for example, by being attached to or coupled to the mandrel 34. In the illustrated embodiment, the compliant element 14 is rotatably supported, for example, by being rotatably attached to or coupled to the mandrel 34. The probe device 10 includes a bearing arrangement generally indicated as 36 for rotatably supporting the compliant element 14.

[0365] As described above, the intermediate member 16 and the compliant element 14 are positioned to define an interface 18 between them, and at least one of the intermediate member 16 and the compliant element 14 is configured and / or operable to hold the fluid 20 located at the interface 18 between the intermediate member 16 and the compliant element 14.

[0366] The configuration of the intermediate member 16 and / or compliant element 14 to hold the fluid 20 placed at the interface 18 can take various different forms.

[0367] For example, the intermediate member 16 and / or compliant element 14 may be configured to hold the fluid placed at the interface, and this may include or be in the form of a surface treatment.

[0368] Figures 5A to 5D of the attached drawings show possible configurations 38a, 38b, 38c, and 38d of the intermediate member 16 and / or compliant element 14 after surface treatment.

[0369] One or more surface treatment processes are applied to the intermediate member 16 and / or the mold used to form the intermediate member 16.

[0370] The surface roughness of the intermediate member 16 is selected based on the frequency and / or wavelength of the ultrasonic beam U.

[0371] For example, the surface roughness may be selected as Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0372] Advantageously, this minimizes or at least reduces wavefront aberration.

[0373] In the illustrated embodiment, the surface treatment is also formed on or otherwise provided on the surface 40 of the compliant element 14 facing the intermediate member 16, and in the illustrated embodiment, the surface 40 is the inner surface of the compliant element 14.

[0374] One or more processes are applied to the compliant element 14 and / or the mold used to form the compliant element 14.

[0375] The surface roughness of the compliant element 14 is selected based on the frequency and / or wavelength of the ultrasonic beam U.

[0376] For example, the surface roughness may be selected as Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0377] Advantageously, this minimizes or at least reduces wavefront aberration.

[0378] As described above, during use, the probe device 10 is placed on the subject W, and the compliant element 14 receives a force that biases it to engage with or strengthen the engagement with the subject W. The transducer configuration 12 is configured and / or operable to direct the ultrasonic beam U toward the subject W, and one or more characteristics of the reflected beam R are detected by the transducer configuration 12 and / or another detection configuration to determine the characteristics, state, health and / or behavior of the subject W. As described above, the fluid 20 is placed within the probe device 10, including the fluid 20 at the interface 18 between the intermediate member 16 and the compliant element 14, and the fluid 20 acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element 14 and further to the subject W. In this probe device 10, one or both of the intermediate member 16 and the compliant element 14 are configured and / or operable to hold the fluid 20 placed at the interface 18 between the intermediate member 16 and the compliant element 14.

[0379] In the illustrated embodiment, the intermediate member 16 and the compliant element 14 can be reconfigured, for example, depending on the applied load, from a first configuration in which the intermediate member 16 and the compliant element 14 are spaced apart from each other, to a second configuration in which the intermediate member 16 engages with the compliant element 14, preventing leakage of the fluid 20 within the interface 18.

[0380] The probe device 10 includes an absorber 42, which is configured and / or operable to absorb ultrasonic waves.

[0381] Advantageously, the absorber 42 prevents undesirable reflected waves and / or signals from affecting the evaluation.

[0382] As described above, the fluid 20 is located within the probe device 10, including the fluid at the interface 18 between the intermediate member 16 and the compliant element 14, where the fluid 20 acts as a coolant and / or internal coupling, facilitating the entry of ultrasonic waves U into the compliant element 14 and further transmission to the subject W. In this probe device 10, one or both of the intermediate member 16 and the compliant element 14 are configured and / or operable to hold the fluid 20 located at the interface 18 between the intermediate member 16 and the compliant element 14.

[0383] The fluid 20 acts as a coolant and / or internal coupling, and is configured and / or operable to facilitate the entry of ultrasonic waves U into the compliant element 14 and further transmission to the subject W.

[0384] In the illustrated embodiment, the fluid 20 comprises or is in the form of a liquid.

[0385] As shown in Figure 6 of the attached drawings, a system generally referred to as 1000 is provided for use in non-destructive evaluation of the subject W, and the system comprises the probe device 10 shown in Figure 1.

[0386] Referring to Figures 7 to 10 in the attached drawings, a perspective view of a probe device, generally indicated as 110, is shown for use in non-destructive evaluation of the subject W.

[0387] As shown in the figure, the probe device 110 comprises a transducer configuration generally referred to as 112, configured and / or operable to direct an ultrasonic beam U toward the subject W; a compliant element generally referred to as 114, configured to engage with the subject W; and an intermediate member generally referred to as 116, interposed between the transducer configuration 112 and the compliant element 114.

[0388] In the illustrated apparatus 110, the probe device 110 is configured and / or operable to control the tilt angle of the compliant element 114 to reduce deviations in the ultrasonic beam U propagating within the subject W.

[0389] During use, the probe device 110 is positioned on the subject W, and the compliant element 114 receives a force that biases the compliant element 114 to engage with or enhance the engagement with the subject W. The transducer configuration 112 is configured and / or operable to direct an ultrasonic beam U toward the subject W, and one or more characteristics of the reflected beam R are detected by the transducer configuration 112 and / or another detection configuration to determine the characteristics, state, health and / or behavior of the subject W. The probe device 110 also includes an inlet configuration generally indicated as 111, which comprises one or more inlets 113. The probe device 110 also includes an outlet configuration generally indicated as 115, which comprises one or more outlets 117. The inlet configuration 111 and the outlet configuration 115 are coupled and / or operablely associated with a fluid configuration generally indicated as 119. The fluid configuration 119 comprises a cooling configuration 121. The probe device 10 comprises a valve configuration generally indicated as 123. Further as described below, the fluid 120 is supplied to the internal volume 130 of the compliant element 114 by the fluid configuration 119 via the inlet configuration 111. The fluid 120 is positioned within the probe device 110, including the fluid 120 at the interface 118 between the intermediate member 116 and the compliant element 114, and the fluid 120 acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element 114 and to the subject W. The fluid 120 is cooled via the cooling configuration 121 before being supplied to the internal volume 130. The fluid 120, whose temperature has risen through the use of the probe device 110, is then removed from the internal volume 130 of the compliant element 114 by the fluid configuration 119 via the outlet configuration 115. While the high-temperature fluid 120 is being removed from the internal volume 130, the fluid configuration 119 simultaneously supplies cooled fluid 120 to the internal volume 130 via the cooling configuration 121 to replace the removed high-temperature fluid 120. The cooling configuration 121 then cools the removed high-temperature fluid 120, and the cooled fluid 120 is resupplied to the internal volume 130 of the compliant element 114 via the inlet configuration 111.In this probe device 110, the probe device 110 is configured and / or operable to control the tilt angle of the compliant element 114 in order to reduce deviations in the ultrasonic beam U propagating within the subject W.

[0390] It has been found that a 1-degree difference in the inclination of the inner and outer surfaces of the compliant element 114 results in a much larger deviation in the path of the ultrasonic beam U within the subject W. For example, the compliant element 114 is often made of a material that reduces the speed at which sound propagates compared to the materials of the intermediate member 116 and the subject W, respectively. Therefore, when the ultrasonic beam U propagates from the intermediate member 116 to the compliant element 114, the beam U is refracted, resulting in a significant change in the angle of the ultrasonic beam U. A similar refraction process occurs when the beam U propagates from the compliant element 114 to the subject W. If the inner and outer surfaces of the compliant element 114 are kept parallel to each other, the angle of the path of the ultrasonic beam U within the subject W is unaffected. Advantageously, the probe device 110 compensates for the deviation in the ultrasonic beam U propagating within the subject W caused by the ultrasonic beam U propagating through the compliant element 114 with non-parallel inner and outer surfaces.

[0391] The probe device 110 includes a passive configuration, generally indicated as 146, for controlling the tilt of the compliant element 114.

[0392] In the illustrated apparatus 110, the passive configuration 146 comprises a plurality of wheels 150, and the wheels 150 of the passive configuration 146 are configured and / or operable to control the alignment of the compliant elements 114.

[0393] As described above, the intermediate member 116 and the compliant element 114 are arranged to define an interface 118 between them. At least one of the intermediate member 116 and the compliant element 114 is configured and / or operable to hold the fluid 120 that is located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0394] During use, the probe device 110 is placed on the subject W, and the compliant element 114 receives a force that biases the compliant element 114 to engage with or strengthen the engagement with the subject W. The transducer configuration 112 is configured and / or operable to direct the ultrasonic beam U toward the subject W, and one or more characteristics of the reflected beam R are detected by the transducer configuration 112 and / or another detection configuration to determine the characteristics, state, health and / or behavior of the subject W. As described above, the fluid 120 is placed within the probe device 110, including the fluid 120 at the interface 118 between the intermediate member 116 and the compliant element 114, and the fluid 120 acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element 114 and to the subject W. In this probe device 110, one or both of the intermediate member 116 and the compliant element 114 are configured and / or operable to hold the fluid 120 located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0395] As described above, the probe device 110 includes a transducer configuration 112 that is configured and / or operable to direct an ultrasonic beam U toward the subject W.

[0396] In the illustrated apparatus 110, the transducer configuration 112 comprises or is configured to include a transducer array 122, and in particular, the transducer configuration 112 comprises or is configured to include a phased array ultrasonic transducer (PAUT) configuration.

[0397] The transducer configuration 112 is configured and / or operable to transmit and / or receive an ultrasonic beam U.

[0398] The transducer configuration 112 is coupled to and / or operablely associated with the ultrasonic driver device 144.

[0399] During use, the ultrasonic beam U is focused using a time delay to generate constitutive interference at the wavefront of concern. Such interference allows energy to be focused at any depth and angle within the object W. To facilitate the generation of such constitutive interference, the transducer configuration 112 includes transducers that transmit / receive independently at different times.

[0400] Alternatively or additionally, as described above, the ultrasonic driver device 144 transmits high-voltage electrical pulses, thereby causing each of the one or more transmitters to transmit an ultrasonic beam U at a separate interval from each of the other transmitters, and the reflection from each transmitted ultrasonic beam U is received by one or more receivers. When multiple receivers receive the reflected ultrasonic beam U, the ultrasonic driver device 144 receives the corresponding signal and records the signal. The recorded data can then be used to perform advanced reconstruction to generate constitutive interference in the wavefront of concern.

[0401] As described above, the probe device 110 includes an intermediate member 116 interposed between the transducer configuration 112 and the compliant element 114.

[0402] In the illustrated apparatus 110, the intermediate member 116 is provided with or has a wedge portion 124.

[0403] The intermediate member 116 is constructed partially or entirely from a plastic material, the plastic material comprising or in the form of a thermoplastic material. In the illustrated embodiment, the plastic material comprises or in the form of a polyetherimide, for example, Ultem(R). Alternatively or additionally, the plastic material may comprise or in the form of a polyimide, for example, Vespel(R). The plastic material may comprise or in the form of a polyamideimide, for example, Duratron(R).

[0404] Advantageously, the intermediate member 116 provides high strength and high temperature capability, facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after a welding process, metal objects during and / or immediately after a metal additive manufacturing process, or composite material parts during and / or immediately after a manufacturing process.

[0405] As shown in Figure 11, the transducer configuration 112 and the intermediate member 116 together form the transducer assembly 126 of the probe device 110.

[0406] At least one of the transducer assembly 126 and the compliant element 114 is configured and / or operable to hold the fluid 120 located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0407] As described above, the probe device 110 includes a compliant element 114 configured to be positioned between the intermediate member 116 and the subject W.

[0408] The compliant element 114 is constructed partially or entirely from an elastomer material, the elastomer material comprising or in the form of a silicone rubber material. In the illustrated embodiment, the compliant element 114 is constructed partially or entirely from high-temperature silicone rubber.

[0409] Advantageously, the compliant element 114 can conform to the shape of the specimen W and provides high strength and high temperature capability, thereby facilitating its use in high-temperature in-process non-destructive evaluation of objects such as welds during and / or immediately after the welding process, metal objects during and / or immediately after the metal additive manufacturing process, or composite material parts during and / or immediately after the manufacturing process.

[0410] The compliant element 114 comprises or is in the form of a cylindrical or substantially cylindrical element.

[0411] The probe device 110 is configured such that the compliant element 114 moves relative to the intermediate member 116. For example, the probe device 110 is configured such that the compliant element 114 rotates around the intermediate member 16 and / or the transducer configuration 112. In the illustrated embodiment, the compliant element 114 includes or is configured to include a rolling element 128, and the compliant element 114 includes or is configured to include a tire, wheel, etc.

[0412] The probe device 110 is configured such that the compliant element 114 moves axially relative to the intermediate member 116.

[0413] The compliant element 114 defines at least partially the internal volume 130. The internal volume 130 comprises or is in the form of a chamber, and the transducer assembly 126 is positioned within the internal volume 130. The probe device 110 comprises a support configuration generally indicated as 132. The support configuration 132 comprises or is in the form of a mandrel 134. When in use, the mandrel 134 forms the axle of the probe device 110.

[0414] The transducer assembly 126 is supported by the mandrel 134, for example, and is attached to the mandrel 134, and the transducer assembly is fixedly coupled to the mandrel 134, for example, and is fixedly attached to the mandrel 134.

[0415] The compliant element 114 is movably supported by a mandrel 134, for example, by being attached to or coupled to the mandrel 134. In the illustrated embodiment, the compliant element 114 is rotatably supported, for example by being rotatably attached to or coupled to the mandrel 134. The probe device 110 includes a bearing arrangement 136 for rotatably supporting the compliant element 114.

[0416] As described above, the intermediate member 116 and the compliant element 114 are arranged to define an interface 116 between them, and at least one of the intermediate member 116 and the compliant element 114 is configured to hold and / or operate on the fluid 120 located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0417] The configuration of the intermediate member 116 and / or compliant element 114 to hold the fluid 120 placed at the interface 118 can take various different forms.

[0418] For example, an embodiment of the configuration of the intermediate member 116 and / or compliant element 114 to hold a fluid placed at the interface includes or is configured to include a surface treatment.

[0419] Figures 12A to 12D of the attached drawings show possible configurations 138a, 138b, 138c, and 138d of the intermediate member 116 and / or compliant element 114 after surface treatment.

[0420] One or more surface treatment processes are applied to the intermediate member 116 and / or to the mold used to form the intermediate member 116.

[0421] The surface roughness of the intermediate member 116 is selected based on the frequency and / or wavelength of the ultrasonic beam U.

[0422] For example, the surface roughness may be selected as Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0423] Advantageously, this minimizes or at least reduces wavefront aberration.

[0424] In the illustrated probe device 110, the surface treatment is also formed on the surface 140 of the compliant element 114 facing the intermediate member 116, or provided otherwise, and in the illustrated embodiment, the surface 140 is the inner surface of the compliant element 114.

[0425] One or more processes are applied to the compliant element 114 and / or the mold used to form the compliant element 114.

[0426] The surface roughness of the compliant element 114 is selected based on the frequency and / or wavelength of the ultrasonic beam U.

[0427] For example, the surface roughness may be selected as Ra ≤ λ / 10, where Ra is the surface roughness and λ is the wavelength.

[0428] Advantageously, this minimizes or at least reduces wavefront aberration.

[0429] As described above, during use, the probe device 110 is placed on the subject W, and the compliant element 114 receives a force that biases the compliant element 114 to engage with or strengthen the engagement with the subject W. The transducer configuration 112 is configured and / or operable to direct an ultrasonic beam U toward the subject W, and one or more characteristics of the reflected beam R are detected by the transducer configuration 112 and / or another detection configuration to determine the characteristics, state, health and / or behavior of the subject W. The probe device 110 also includes an inlet configuration generally indicated as 111, which comprises one or more inlets 113. The probe device 110 also includes an outlet configuration generally indicated as 115, which comprises one or more outlets 117. The inlet configuration 111 and the outlet configuration 115 are coupled and / or operablely associated with a fluid configuration generally indicated as 119. The fluid configuration 119 comprises a cooling configuration 121. The probe device 10 comprises a valve configuration generally indicated as 123. As described above, the fluid 120 is supplied to the internal volume 130 of the compliant element 114 by the fluid configuration 119 via the inlet configuration 111. The fluid 120 is arranged within the probe device 110, including the fluid 120 at the interface 118 between the intermediate member 116 and the compliant element 114, and the fluid 120 acts as a coolant and / or internal coupling to facilitate the transmission of ultrasound to the compliant element 114 and to the subject W. The fluid 120 is cooled via the cooling configuration 121 before being supplied to the internal volume 130. The fluid 120, whose temperature has risen through the use of the probe device 110, is then removed from the internal volume 130 of the compliant element 114 by the fluid configuration 119 via the outlet configuration 115. While the high-temperature fluid 120 is being removed from the internal volume 130, the fluid configuration 119 simultaneously supplies cooled fluid 120 to the internal volume 130 via the cooling configuration 121 to replace the removed high-temperature fluid 120. The cooling configuration 121 then cools the removed high-temperature fluid 120, and the cooled fluid 120 is resupplied to the internal volume 130 of the compliant element 114 via the inlet configuration 111.In this probe device 110, one or both of the intermediate member 116 and the compliant element 114 are configured and / or operable to hold the fluid 120 located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0430] In the illustrated apparatus 110, the intermediate member 116 and the compliant element 114 can be reconfigured from a first configuration in which the intermediate member 116 and the compliant element 114 are spaced apart from each other to a second configuration in which, for example, in response to an applied load, the intermediate member 116 engages with the compliant element 114 to prevent the fluid 120 in the interface 118 from leaking out.

[0431] The probe device 110 includes an absorber 142, which is configured and / or operable to absorb ultrasonic waves.

[0432] Advantageously, the absorber 142 prevents undesirable reflected waves and / or signals from affecting the evaluation.

[0433] As described above, the fluid 120 is located within the probe device 110, including the fluid at the interface 118 between the intermediate member 116 and the compliant element 114, and the fluid 120 acts as a coolant and / or internal coupling to facilitate the entry of ultrasonic waves U into the compliant element 114 and further transmission to the subject W. In the illustrated probe device 110, one or both of the intermediate member 116 and the compliant element 114 are configured and / or operable to hold the fluid 120 located at the interface 118 between the intermediate member 116 and the compliant element 114.

[0434] The fluid 120 is configured and / or operable to act as a coolant and / or internal coupling to facilitate the entry of ultrasonic waves U into the compliant element 114 and further transmission to the subject W.

[0435] In the illustrated apparatus 110, the fluid 120 comprises or is in the form of a liquid.

[0436] As shown in Figure 13, a system generally referred to as 2000 is provided for use in non-destructive evaluation of the subject W, and the system comprises the probe device 110 shown in Figure 7.

[0437] As shown in Figure 14, a graph illustrating error propagation due to angular deviation is provided.

[0438] As shown in Figure 15, a graph is provided illustrating the parametric analysis of beam angle errors for various angles of the compliant element, relative to the intended ultrasonic beam angle.

[0439] As shown in Figure 16, an alternative probe device, generally indicated as 210, is provided for use in non-destructive evaluation of the subject W.

[0440] It has been found that a 1-degree difference in the inclination of the inner and outer surfaces of the compliant element 214 results in a much larger deviation in the path of the ultrasonic beam U within the subject W. For example, the compliant element 214 is often made of a material that reduces the speed at which sound propagates compared to the materials of the intermediate member 216 and the subject W, respectively. Therefore, when the ultrasonic beam U propagates from the intermediate member 216 to the compliant element 214, the beam U is refracted, resulting in a significant change in the angle of the ultrasonic beam U. A similar refraction process occurs when the beam U propagates from the compliant element 214 to the subject W. If the inner and outer surfaces of the compliant element 214 are kept parallel to each other, the angle of the path of the ultrasonic beam U within the subject W is unaffected. Advantageously, the probe device 210 compensates for the deviation in the ultrasonic beam U propagating within the subject W caused by the ultrasonic beam U propagating through the compliant element 214, where the inner and outer surfaces are not parallel.

[0441] The probe device 210 is coupled to and / or operably associated with an active configuration generally indicated as 252 for controlling the tilt of the compliant element 214, the active configuration 252 comprising a robotic arm 254.

[0442] The active configuration 252 comprises a sensor configuration generally referred to as 256, which measures the angle of the subject W and / or the angle between the sensor configuration 256 and the subject W, and is configured and / or operable to adjust the inclination of the compliant element 214 in real time accordingly. The sensor configuration 256 comprises one or more sensors. For example, the sensor configuration 256 comprises one or more non-contact distance measuring sensors such as a laser profiler, an IR distance sensor and / or an ultrasonic distance sensor. For example, the sensor configuration also comprises one or more force and / or torque sensors.

[0443] As shown in Figure 17, schematic diagrams of the transducer configuration 312 and intermediate member 316 of the alternative probe device 310 are provided. It should be understood that device 310 is similar to device 10, and similar components are referred to using similar reference numerals incremented by 300.

[0444] As shown in Figure 18, cross-sectional views of the transducer configuration 412 and the multiple intermediate members 416 of the alternative probe device 410 are provided. As shown, the transducer assembly 426 is arranged to form a transmit / receive split longitudinal wave (TRL) configuration. Each of the multiple intermediate members 416 is angled so that the ultrasonic beam U transmitted by the multiple transducers 422 of the transducer configuration 412 converges to the focal point. It should be understood that the device 410 is similar to the device 10, and similar components are referred to using similar reference numerals incremented by 400.

[0445] As shown in Figure 19, a perspective view of the transducer configuration 512 of the alternative probe device 510 is provided. As shown, the transducer configuration 512 comprises or takes the form of a matrix array. It should be understood that device 510 is similar to device 10, and similar components are referred to using similar reference numerals incremented by 500.

[0446] Figure 20 shows a method for non-destructive evaluation of a test subject, which comprises or is in the form of a non-welded structure.

[0447] As shown in Figure 20, the method includes the steps of emitting ultrasound to a subject, receiving ultrasound returning from the subject, acquiring a plurality of signal sets including a first signal set and a second signal set, and processing the first signal set and the second signal set to provide evaluation data related to the subject.

[0448] The first signal set includes a first sequence of first data elements over a first period. Each first data element includes a first variable value for a variable and a first time value for that first variable value. The first period includes a first time subperiod.

[0449] The second signal set includes a second sequence of second data elements over a second time period. Each second data element includes a second variable value for the variable and a second time value for that second variable value. The second time period includes a second time sub-period.

[0450] The first time sub-period and the second time sub-period contain the same time value.

[0451] The processing of the first and second signal sets determines the modified signal set that contributes to the evaluation data.

[0452] The corrected signal set includes a corrected time sub-period that includes the same time values ​​as the first and second time sub-periods, and, with respect to the time value, includes a representation of the first variable value and a representation of the second variable value for that time value if the first and second variable values ​​are in a given relationship with respect to that time value, and / or, if the first and second variable values ​​are not in a given relationship with respect to the time value, includes either a representation of the first variable value or a representation of the second variable value for that time value.

[0453] Furthermore, referring to Figures 21, 22, and 23 of the attached drawings, an example of the method shown in Figure 20 is illustrated.

[0454] Figure 21 shows a method for non-destructive evaluation of a subject, where the subject comprises or is in the form of a non-welded structure in the form of an object constructed using additive manufacturing technology.

[0455] In the illustrated method, the object comprises or is in the form of an object constructed using metal additive manufacturing, more specifically wire arc additive manufacturing (WAAM).

[0456] Therefore, the method shown in Figure 21 can be defined as a method for use in non-destructive evaluation of objects constructed using additive manufacturing technology. Therefore, the method can further be defined as a method for use in non-destructive evaluation of objects constructed using metal additive manufacturing technology such as wire arc additive manufacturing (WAAM), but is not limited to this method.

[0457] As shown in Figure 21, the method includes emitting ultrasound to a subject, receiving ultrasound returning from the subject, acquiring multiple signal sets including a first signal set and a second signal set, and processing the first signal set and the second signal set to provide evaluation data about the subject.

[0458] In the illustrated method, the method further includes a preliminary step of providing a probe device and positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

[0459] The method includes placing a probe device near the subject.

[0460] In the illustrated method, the method includes positioning the probe device in contact with the subject.

[0461] However, it will be understood that alternative methods may involve positioning the probe device adjacent to the subject without contact with the subject.

[0462] Similar to the method shown and described in Figure 20, in the method of Figure 21, the first signal set includes a first sequence of first data elements, the first sequence of first data elements spanning a first time period. Each first data element includes a first variable value for a variable and a first time value for that first variable value. The first time period includes a first time sub-period.

[0463] The second signal set includes a second sequence of second data elements, the second sequence of second data elements spanning a second time period. Each second data element includes a second variable value for that variable and a second time value for that second variable value. The second time period includes a second time sub-period.

[0464] The first time sub-period and the second time sub-period contain the same time value.

[0465] The processing of the first and second signal sets determines the modified signal set that contributes to the evaluation data.

[0466] The corrected signal set includes a corrected time sub-period that includes the same time values ​​as the first and second time sub-periods, and, with respect to the time value, includes a representation of the first variable value and a representation of the second variable value for that time value if the first variable value and the second variable value are in a given relationship with respect to that time value, and / or, if the first variable value and the second variable value are not in a given relationship with respect to that time value, includes either a representation of the first variable value or a representation of the second variable value for that time value.

[0467] Figure 22 shows another example of the method shown in Figure 20, where the subject comprises or is in the form of a non-welded structure in the form of an object constructed from a composite material.

[0468] Therefore, the method shown in Figure 22 can be defined as a method for use in non-destructive evaluation of objects constructed from composite materials.

[0469] As shown in Figure 22, the method includes emitting ultrasound to a subject, receiving ultrasound returning from the subject, acquiring multiple signal sets including a first signal set and a second signal set, and processing the first signal set and the second signal set to provide evaluation data related to the subject.

[0470] In the illustrated method, the method further includes a preliminary step of providing a probe device and positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

[0471] The method includes placing a probe device near the subject.

[0472] In the illustrated method, the method includes positioning the probe device in contact with the subject.

[0473] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0474] Similar to the method shown and described in Figure 20, in the method of Figure 22, the first signal set includes a first sequence of first data elements, the first sequence of first data elements spanning a first time period. Each first data element includes a first variable value for a variable and a first time value for that first variable value. The first time period includes a first time sub-period.

[0475] The second signal set includes a second sequence of second data elements, the second sequence of second data elements spanning a second time period. Each second data element includes a second variable value for the variable and a second time value for the second variable value. The second time period includes a second time sub-period.

[0476] The first time sub-period and the second time sub-period contain the same time value.

[0477] The processing of the first and second signal sets determines the modified signal set that contributes to the evaluation data.

[0478] The corrected signal set includes a corrected time sub-period that includes the same time values ​​as the first and second time sub-periods, and, with respect to the time value, includes a representation of the first variable value and a representation of the second variable value for that time value if the first variable value and the second variable value are in a given relationship with respect to that time value, and / or, if the first variable value and the second variable value are not in a given relationship with respect to that time value, includes either a representation of the first variable value or a representation of the second variable value for that time value.

[0479] Figure 23 shows another example of the method shown in Figure 20, where the subject comprises or is in the form of a non-welded structure in the form of an object constructed from the body of a human or animal.

[0480] Therefore, the method shown in Figure 23 can be defined as a method for non-invasive assessment of the human or animal body.

[0481] In the illustrated method, the method further includes a preliminary step of providing a probe device and positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

[0482] The method includes placing a probe device near the subject.

[0483] In the illustrated method, the method includes positioning the probe device in contact with the subject.

[0484] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0485] Similar to the method shown and described in Figure 20, in the method of Figure 23, the first signal set includes a first sequence of first data elements, the first sequence of first data elements spanning a first time period. Each first data element includes a first variable value for a variable and a first time value for that first variable value. The first time period includes a first time sub-period.

[0486] The second signal set includes a second sequence of second data elements, the second sequence of second data elements spanning a second time period. Each second data element includes a second variable value for the variable and a second time value for that second variable value. The second time period includes a second time sub-period.

[0487] The first time sub-period and the second time sub-period contain the same time value.

[0488] The processing of the first and second signal sets determines the modified signal set that contributes to the evaluation data.

[0489] The corrected signal set includes a corrected time sub-period that includes the same time values ​​as the first and second time sub-periods, and, with respect to the time value, includes a representation of the first variable value and a representation of the second variable value for that time value if the first variable value and the second variable value are in a given relationship with respect to that time value, and / or, if the first variable value and the second variable value are not in a given relationship with respect to that time value, includes either a representation of the first variable value or a representation of the second variable value for that time value.

[0490] Figure 24 shows another method of non-destructive evaluation of a subject, the subject having or being in the form of a non-welded structure.

[0491] As shown in Figure 24, the method includes the steps of radiating ultrasound into a volume of a non-welded structure provided at a heated temperature above the ambient temperature, receiving at least a portion of the ultrasound returning from the non-welded structure, acquiring a plurality of signal sets, and processing one or more of the plurality of signal sets to provide evaluation data related to the non-welded structure, wherein the processing includes correction for the temperature within the volume of the subject at the heated temperature.

[0492] Furthermore, referring to Figures 25 and 26 of the attached drawings, an example of the method shown in Figure 24 is illustrated.

[0493] Figure 25 shows a method for non-destructive evaluation of a subject, where the subject comprises or is in the form of a non-welded structure in the form of an object constructed using additive manufacturing technology.

[0494] In the illustrated method, the object comprises or is in the form of an object constructed using metal additive manufacturing, more specifically wire arc additive manufacturing (WAAM).

[0495] Therefore, the method shown in Figure 25 can be defined as a method for use in non-destructive evaluation of objects constructed using additive manufacturing technology. Therefore, this method can further be defined as a method for use in non-destructive evaluation of objects constructed using metal additive manufacturing technology such as wire arc additive manufacturing (WAAM), but is not limited to this method.

[0496] As shown in Figure 25, the method includes the steps of radiating ultrasound into a volume of a non-welded structure provided at a heated temperature above the ambient temperature, receiving at least a portion of the ultrasound returning from the non-welded structure, acquiring a plurality of signal sets, and processing one or more of the plurality of signal sets to provide evaluation data related to the non-welded structure, wherein the processing includes correction for the temperature within the volume of the subject at the heated temperature.

[0497] In the illustrated method, the method further includes a preliminary step of providing the subject at a temperature above ambient temperature by heating during the evaluation.

[0498] The method includes placing a probe device near the subject.

[0499] In the illustrated method, the method includes positioning the probe device in contact with the subject.

[0500] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0501] Similar to the method shown and described in Figure 24, in the method of Figure 25, the subject is provided in a heated state above ambient temperature by heating during evaluation, and the process includes correction for the temperature within the volume of the subject at the heated state.

[0502] Figure 26 shows another example of the method shown in Figure 24, where the subject comprises or is in the form of a non-welded structure in the form of an object constructed from a composite material.

[0503] Therefore, the method shown in Figure 26 can be defined as a method for use in non-destructive evaluation of objects constructed from composite materials.

[0504] As shown in Figure 26, the method includes the steps of: radiating ultrasound into a volume of a non-welded structure provided at a heated temperature above the ambient temperature; receiving at least a portion of the ultrasound returning from the non-welded structure; acquiring a plurality of signal sets; and processing one or more of the plurality of signal sets to provide evaluation data related to the non-welded structure, wherein the processing includes correction for the temperature within the volume of the subject at the heated temperature.

[0505] In the illustrated method, the method further includes a preliminary step of providing the subject at a temperature above ambient temperature by heating during the evaluation.

[0506] The method includes placing a probe device near the subject.

[0507] In the illustrated method, the method includes positioning the probe device in contact with the subject.

[0508] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0509] Similar to the method shown and described in Figure 24, in the method of Figure 26, the subject is provided in a heated state above ambient temperature by heating during evaluation, and the process includes correction for the temperature within the volume of the subject at the heated state.

[0510] Figure 27 shows another method of non-destructive evaluation of a subject, which comprises or is in the form of a non-welded structure.

[0511] As shown in Figure 27, the method includes the steps of passing ultrasound from the transducer of an ultrasonic probe to a non-welded structure, detecting reflected ultrasound from the non-welded structure, supplying coolant to the internal volume of the probe through the coolant inlet of the probe while the ultrasound is passing, and removing the coolant from the internal volume of the probe through the coolant outlet of the probe while the ultrasound is passing.

[0512] The ultrasonic probe comprises an axial element. The ultrasonic emission transducer is mounted on the axial element. Two or more support elements are rotatably mounted relative to the axial element. A compliant element is mounted on two or more support elements and provides a continuous surface in at least one direction. The two or more support elements and the compliant element at least partially define the internal volume of the probe, and the transducer is housed within the internal volume.

[0513] Furthermore, referring to Figures 28 and 29 of the attached drawings, an example of the method shown in Figure 27 is illustrated.

[0514] Figure 28 shows a method for non-destructive evaluation of a test subject, which comprises or is in the form of a non-welded structure in the form of an object constructed using additive manufacturing technology.

[0515] In the illustrated method, the object being constructed comprises or is in the form of an object constructed using metal additive manufacturing, more specifically wire arc additive manufacturing (WAAM).

[0516] Therefore, the method shown in Figure 28 can be defined as a method for use in the non-destructive evaluation of objects constructed using additive manufacturing technology. Therefore, this method can further be defined as a method for use in the non-destructive evaluation of objects constructed using metal additive manufacturing technology such as wire arc additive manufacturing (WAAM), but is not limited to this method.

[0517] As shown in Figure 28, the method includes the steps of passing ultrasound from the transducer of an ultrasonic probe to a non-welded structure, detecting reflected ultrasound from the non-welded structure, supplying coolant to the internal volume of the probe through the coolant inlet of the probe while the ultrasound is passing, and removing the coolant from the internal volume of the probe through the coolant outlet of the probe while the ultrasound is passing.

[0518] The method may include a preliminary step of providing an ultrasonic probe and positioning at least one section of the compliant elements of the ultrasonic probe in contact with an object constructed using metal additive manufacturing.

[0519] The method includes placing a probe device near the subject.

[0520] In the illustrated method, the method includes positioning a probe device in contact with the subject.

[0521] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0522] Similar to the method shown and described in Figure 27, in the method of Figure 28, the ultrasonic probe comprises an axial element. An ultrasonic emitting transducer is mounted on the axial element. Two or more support elements are rotatably mounted relative to the axial element. A compliant element is mounted on two or more support elements and provides a continuous surface in at least one direction. The two or more support elements and the compliant element at least partially define the internal volume of the probe, and the transducer is housed within the internal volume.

[0523] Figure 29 shows another example of the method shown in Figure 27, where the subject is a non-welded structure in the form of an object constructed from a composite material. Thus, the method shown in Figure 29 can be defined as a method for use in non-destructive evaluation of objects constructed from composite materials. As shown in Figure 29, the method includes the steps of passing ultrasound from the transducer of an ultrasonic probe to a non-welded structure, detecting reflected ultrasound from the non-welded structure, supplying coolant to the internal volume of the probe through the coolant inlet of the probe during the passage of ultrasound, and removing the coolant from the internal volume of the probe through the coolant outlet of the probe during the passage of ultrasound.

[0524] The method may include a preliminary step of providing an ultrasonic probe and positioning at least one section of the compliant elements of the ultrasonic probe in contact with an object constructed using metal additive manufacturing.

[0525] The method includes placing a probe device near the subject.

[0526] In the illustrated method, the method includes positioning a probe device in contact with the subject.

[0527] However, in an alternative method, the probe device may be positioned adjacent to the subject without contacting the subject.

[0528] Similar to the method shown and described in Figure 27, in the method of Figure 29, the ultrasonic probe comprises an axial element. An ultrasonic emitting transducer is mounted on the axial element. Two or more support elements are rotatably mounted relative to the axial element. A compliant element is mounted on two or more support elements and provides a continuous surface in at least one direction. The two or more support elements and the compliant element define at least partially the internal volume of the probe, and the transducer is housed within the internal volume.

[0529] Figures 30 to 40 in the attached drawings show probe devices for implementing the methods shown in Figures 27 to 29.

[0530] Figure 30 shows a multi-axis robot 1007, which is equipped with an arm 1009, and a probe 1013 is provided at the distal end 1011 of the arm 1009, as schematically shown.

[0531] Figure 31 is a perspective view of one embodiment of the probe 1013. The rotation axis RR extends through the probe 1013. A first mounting position 1020 is provided on the rotation axis, and together with this, a second mounting position 1022 is provided on the other side of the probe 1013. The first mounting position 1020 and the second mounting position 1022 are for attaching the probe 1013 to the robot 1007 in a manner that allows the probe 1013 to rotate as it moves forward on the surface of object 1.

[0532] The probe 1013 is provided with rigid end structures 1024a and 1024b at each end, which are connected by bolts 1025 and provide an annular mounting portion 1026 for a generally cylindrical connecting element 1028.

[0533] A manifold element 1030 is provided, which is connected to a first mounting position 1020 and extends axially from there. The manifold element 1030 includes a cooling fluid inlet 1032, which is connected to a cooling fluid supply conduit (not shown) when in use, and a cooling fluid outlet 1034, which is connected to a cooling fluid discharge conduit (also not shown) when in use.

[0534] Figure 32 is a cross-sectional plan view of the probe shown in Figure 31, and also shows many of the features described above.

[0535] Referring to Figure 33, in the cross-sectional side view of the probe in Figure 31, the manifold element 1030 is connected to the first mounting position 1020 in fluid communication. The first inlet bore section 1036 is connected to the second inlet bore section 1038, and the second inlet bore section 1038 leads to the internal volume 1042 of the probe 1013 via the conduit 1040, thereby forming the first fluid connection. The first outlet bore section 1044 is connected to the second outlet bore section [not shown], and the second outlet bore section is led out from the internal volume 1042 of the probe 1013, thereby forming the second fluid connection.

[0536] The internal volume 1042 extends between the opposing wall sections 1046a and 1046b of the coupling element 1028, and also between the opposing internal surfaces 1048a and 1048b of the rigid end structures 1024a and 1024b. The internal volume 1042 is filled with coolant to a level at least exceeding the maximum vertical extension 1050 of the transducer 1052.

[0537] The connecting element 1028 is a single piece of compliant material, which will be discussed further below. The connecting element 1028 is provided with a generally orthogonal cylindrical main body 1054 and inwardly folded rims 1056a and 1056b at both ends. The rims 1056a and 1056b are compressed between an external element 1024a and an internal element 1024b, respectively, which form a rigid end structure 1024a. The external element 1024a and the opposing internal element 1024b are connected to each other by a series of releasable fasteners, in this case bolts 1025.

[0538] Therefore, as the probe 1013 rolls on the surface of the object, different parts of the main body 1054 of the coupling element 1028 come into contact with the object, and the external element 1024a and internal element 1024b that form the rigid end structure also rotate.

[0539] The rigid end structures 1024a and 1024b can rotate freely relative to the axial element 1064, and the extension of the axial element 1064 provides a first mounting position 1020. The first axial seal 1066 and the second axial seal 1068 provide seals that allow rotation while providing coolant leakage between the axial element 1064 and the rigid end structure 1024.

[0540] The second axial element 1070 is connected to the axial element 1064 by a series of releasable fasteners 1072. The second axial element 1070 provides mounting for the transducer 1052, the anti-echo block 1074, and the ultrasonic transmission block 1076.

[0541] Therefore, the transducer 1052, the anti-echo block 1074, and the transmission block 1076, together with the second axial element 1070, the axial element 1064, and the first mounting position 1020, do not rotate when the probe 1013 rolls over the surface of the object. Thus, the transducer 1070 and its associated components are always maintained in the same sensing orientation facing the object.

[0542] As a result of the above configuration, when the probe 1013 rolls on the surface of the object, relative motion occurs between the inner surface 1078 of the coupling element 1028 and the radial surface 1080 of the transmission block 1076.

[0543] A mounting element 1082 is also attached to the second axial element 1070, and the mounting element 1082 carries a thermistor 1084 for detecting the temperature of the internal roller probe region at a position 1086 close to the inner surface 1078 that contacts the object.

[0544] As shown in Figures 35 to 37, alternative embodiments of the probe 1013, transducer 1052, and transmission block 1076 can be provided. As shown in Figure 35, the transducer 1052 is attached to the inclined axially opposing surface 1088 of the transmission block 1076 by a fastener 1092. The transmission block 1076 includes a coolant inlet 1093 and a coolant outlet 1094. As shown in Figure 36, the coolant inlet 1093 leads to a meandering passage 1095, and thus to a coolant supply outlet 1096 that is in fluid communication with the internal volume 1042 of the probe 1013. A similar structure on the other side of the transmission block 1076 draws coolant from the internal volume through a coolant withdrawal inlet and leads to a second meandering passage, and thus to a coolant outlet 1094. These passages and their configurations help to cool the transmission block 1076.

[0545] The axially opposing surface 1088 of the transmission block 1076 and / or the radially opposing surface 1090 of the transducer 1052 may be provided with gaps, slots, or grooves to facilitate the flow of coolant between the two surfaces.

[0546] For example, referring to Figure 36, the inclined axially opposed surface 1088 has an intersection with a second axially opposed surface 1097, the surface 1097 being approximately parallel to the axis of rotation. The transducer 1052 terminates near the intersection. As shown in detail in Figure 36, a channel 1098, such as a groove, is provided in the transmission block 1076. The channel 1098 improves the reach of the coolant to the gap 1092 between the axially opposed surface 1088 of the transmission block 1076 and the radially opposed surface 1090 of the transducer 1052. The channel 1098 is in fluid communication with a series of additional grooves 1099 on the axially opposed surface 1088 of the transmission block 1076 to further facilitate the flow of coolant to the gap 1092. The channel 1098 and / or additional channels 1099 may be provided in the transducer 1052 and / or the transmission block 1076.

[0547] As shown in Figure 37 and the detailed view of Figure 37, channel 1098 extends across the width of the transmission block 1076 from one side to the other. Additional channels 1099 are arranged at regular intervals along channel 1098 and extend along the inclined axially opposed surface 1088 in the direction away from channel 1098.

[0548] As another possible detail, considering the rotation as the probe 1013 moves in direction A, each of the leading edge 1100 and trailing edge 1102 of the transmission block 1076 is chamfered. Thus, as the transmission block 1076 moves substantially through the coolant during rotation, the coolant is facilitated by the chamfer of the leading edge 1100 toward the gap 1108 between the radially opposing surface 1080 of the transmission block 1076 and the inner surface 1078 of the coupling element 1028. This facilitates the continuous presence of the coolant between the radial surface 1080 and the inner surface 1078, which is highly beneficial for the passage of ultrasound across the interface between the transmission block 1076 and the coupling element 1028. The continuous presence of the coolant is also beneficial for the cooling of the radial surface 1080.

[0549] The distance between the rotation axis RR and the object 1 being probed is such that, during use, the object 1 pushes the coupling element 1028 toward the axis and thus brings it into good contact with the transmission block 1076, and the coupling element 1028 is compressed between the object 1 and the transmission block 1076.

[0550] As shown in Figure 35, another possible detail is that the axially opposed surface 1088 of the transmission block 1076 extends more along the axis and perpendicular to the axis than the radially opposed surface 1090 of the transducer 1052. As the transmission block 1076 and transducer 1052 are moved through the coolant by the rotation of the probe 1013, this geometry promotes the coolant to the junction between the transmission block 1076 and transducer 1052, and consequently to the gap 1092 between them. The direction of the coolant flow entering the device along the conduit 1042 also promotes flow towards the gap 1092.

[0551] In another possible detail shown in Figure 38, the radially opposing surface 1080 of the transmission block 1076 comprises a series of interface channels 1300. These are recessed into the radially opposing surface 1080 of the curved surface that faces the inner surface 1078 of the coupling element 1028 when in use. The interface channels 1300 extend along the entire length of the transmission block 1076 and extend parallel to the axis, but other extensions and shapes may also be provided.

[0552] The continuous presence of a coolant in the gap 1092 between the axially opposing surface 1088 of the transmission block 1076 and the radially opposing surface 1090 of the transducer 1052 is highly beneficial for the passage of ultrasonic waves across the interface between them.

[0553] Regarding the transmission of ultrasound, the transmission block 1076 is manufactured from polyetherimide because it provides the desired heat resistance and the ability to withstand repeated cycles of temperature changes. Furthermore, this material possesses the necessary acoustic properties to balance with the other components.

[0554] For monitoring purposes, thermistor 1084 is housed in a further block of polyetherimide, offset laterally from the transmission block 1076, so as not to interfere with the ultrasonic propagation role of the transmission block 1076. At the same time, the position of thermistor 1084 is still effective in ensuring that it does not approach the temperature constraints of the components. If it does approach, probe 1013 may be removed from the object to prevent damage to the components. The block providing thermistor 1084 may be mounted on the transmission block 1076 in other embodiments, and thermistor 1084 may be incorporated into the transmission block 1076 in other embodiments. With respect to the passage of ultrasound, the coupling element 1028 is a high-temperature-compatible silicone rubber. The selected material can withstand temperatures above 350°C for extended periods. Such a material may have an attenuation of 0.87 dB / mm and an acoustic impedance of 1.12 MRayls at 5 MHz, and therefore has good compatibility with other materials used.

[0555] Regarding the thickness of the coupling element 1028, a balance is struck between the fact that increasing the thickness provides more thermal insulation to the probe contents and the fact that increasing the thickness results in an unfavorable increase in damping. A thickness between 4 mm and 8 mm is suitable for such materials under the operating conditions under consideration.

[0556] The material selected for the coupling element 1028 also provides sufficient compliance to conform to the surface of the object under moderate applied force levels. High force levels are undesirable in terms of the equipment required to generate them and move the device on the test specimen. Since the surfaces of objects encountered in real-world situations are not highly finished or smooth, a compliant material is necessary to obtain good contact for ultrasonic transmission without excessive loss.

[0557] Regarding the transmission of ultrasound, the anti-echo block 1074 plays a crucial role in preventing ultrasound from reflecting within the probe and causing noise or other negative effects on the probe. Hydrogenated nitrile rubber (HNBR), particularly in its N-filled form, was found to be a suitable material due to the 6.4 dB / mm attenuation provided at 5 MHz.

[0558] All of these features play a role in assisting the successful acoustic coupling of the probe to an object via a surface encountered in the real world.

[0559] To help the object withstand the elevated surface temperature, the coolant circuit of probe 1013 is used.

[0560] Figure 39 shows a schematic of the coolant circuit in one embodiment. The coolant reservoir 1100 supplies coolant to the pump 1104 via the conduit 1102 and to the cooling fluid inlet 1032 provided on the probe 1013 via the second conduit 1106.

[0561] Within the internal volume 1042, the coolant can circulate freely throughout the entire volume of the internal volume, including around the transducer 1052, around the transmission block 1076, through the gap between them, around at least the lower part of the coupling element 1028, and through the gap 1092 between the radially opposing surfaces 1080 of the coupling element 1028 and the transmission block 1076.

[0562] Returning to Figure 39, the coolant is discharged from the internal volume 1042 through the cooling fluid outlet 1034 to the third conduit 1108. Temperature sensors in the third conduit and / or in the internal volume 1040 may be used to ensure that the cooling is as desired and to control the pump speed to increase or decrease the cooling. The third conduit 1108 leads to the heat exchanger 1110, which provides cooling of the coolant in preparation for reuse. The fourth conduit 1112 takes the cooled coolant from the heat exchanger 1110 and returns the coolant to the reservoir 1100 in preparation for reuse.

[0563] The use of active cooling for probe 1013 and its elements is beneficial in that it allows probe 1013 to be used for extended periods on high-temperature object surfaces.

[0564] Referring to Figure 40, this shows a first temperature plot 1200 and a second temperature plot 1202, both of which represent the time the probe is in contact with the hot object. The first temperature plot 1200 relates to a probe 1013 according to the present disclosure, which includes a circulating coolant. This shows that this approach is successful in keeping the internal temperature of the probe 1013 well within the operating limits. Active cooling ensures that the transducer is kept below 55-60°C, which is the maximum operating temperature applicable to most desired types of transducers.

[0565] The second temperature plot 1202 relates to a probe having similar internal components, but limited to one in which the coolant volume is fixed and sealed within the probe's internal volume. As heat is transferred to and accumulated within the probe, the temperature clearly rises over time, and after a relatively short period, the temperature exceeds a reliable operating threshold of 50°C. In practice, such a probe must be removed from the object before reaching the 50°C threshold, and monitoring cannot be performed until the probe itself has cooled down.

[0566] Regarding coolants, air has poor heat capacity and conductivity for active cooling. Water is also unsuitable because its acoustic impedance of 1.5 MRayls does not match well with other components. For example, providing a coolant in the form of a water-soluble oil can have an acoustic impedance of 1.1 MRayls, and therefore better matches the acoustic impedance of the transmission block [approximately 1.1 MRayls].

[0567] The transducer 1052 provides a 5 MHz 64-element phased array and is mounted to generate ultrasonic waves at a 55° angle to an object. A pitch of 0.5 mm and an elevation of 10 mm may be used. The inclined beam is beneficial in that it allows for complete inspection of the object from laterally spaced positions. Often, these laterally spaced positions are better suited to good contact between the probe and the object. This type of transducer and transmission block configuration may be used to provide a sector scanning beam defined by an upper end beam [inclined away from the perpendicular to the transducer surface] and a lower end beam [close to the perpendicular to the transducer surface] that are emitted.

[0568] In terms of the performance required of a probe with respect to high temperature performance, this disclosure provides a probe capable of inspecting objects at approximately 300°C for extended periods.

[0569] Although the coupling is dry, it still achieves the necessary level for ultrasonic propagation to and from the object across the interface.

[0570] The high-temperature polymers used as bonding components can withstand prolonged contact with objects at such temperatures and successfully propagate ultrasound to and from the interface.

[0571] Coolant, and by extension the gap filled with coolant, can also effectively propagate ultrasound to and from the transmission block.

[0572] Since the transmission block is exposed almost entirely to ambient temperature, it is provided with optimal propagation characteristics, and there is no need to select a high-temperature resistant material with inferior ultrasonic propagation characteristics.

[0573] It will be understood that various modifications may be made without departing from the scope of the claimed invention.

Claims

1. A probe device for use in non-destructive evaluation of a subject, A transducer configuration configured and / or operable to direct an ultrasonic beam toward the subject, A compliant element configured to engage with the subject, An intermediate member interposed between the transducer configuration and the compliant element Equipped with, The intermediate member and the compliant element are arranged to define an interface between them. A probe device wherein at least one of the intermediate member and the compliant element is configured and / or operable to hold a fluid disposed at the interface between the intermediate member and the compliant element.

2. The probe device according to claim 1, wherein the configuration of the intermediate member and / or the compliant element for holding the fluid arranged at the interface includes or is configured to include a surface treatment.

3. The probe device according to claim 2, wherein the surface treatment is formed or provided on the distal surface of the intermediate member.

4. The aforementioned surface treatment is One or more protrusions formed on or provided on the intermediate member, One or more ridges formed on or provided on the intermediate member, One or more grooves formed or provided on the intermediate member, One or more channels formed on or provided on the intermediate member, and / or One or more bores formed or provided on the intermediate member The probe device according to claim 2 or 3, comprising or having the same configuration.

5. The aforementioned surface treatment is Milling, for example, CNC milling, Machining, for example, laser machining, Sculpture, Etching, for example, acid etching, and / or Sandblasting A probe device according to claim 2, 3, or 4, formed by one or more of the following.

6. The probe device according to claim 2, 3, or 4, wherein the surface roughness Ra of the intermediate member is selected based on the wavelength λ of the ultrasonic beam, where Ra ≤ λ / 10.

7. The probe device according to any one of claims 2 to 6, wherein the surface treatment is formed or provided on the surface of the compliant element facing the intermediate member.

8. The aforementioned surface treatment is One or more protrusions formed on or provided on the compliant element, One or more ridges formed on or provided on the compliant element, One or more grooves formed or provided on the compliant element, One or more channels formed on or provided on the compliant element, and / or One or more bores formed or provided on the compliant element The probe device according to claim 7, comprising or having the same configuration.

9. The aforementioned surface treatment is Milling, for example, CNC milling, Machining, for example, laser machining, Sculpture, Etching, for example, acid etching, and / or Sandblasting A probe device according to claim 7 or 8, formed by one or more of the following.

10. The probe device according to claim 7, 8, or 9, wherein the surface roughness Ra of the compliant element is selected based on the wavelength λ of the ultrasonic beam, where Ra ≤ λ / 10.

11. The probe device according to any one of claims 1 to 10, wherein the transducer configuration comprises one or more transducers.

12. One or more of the transducers are Piezoelectric transducer, Eddy current transducer, Capacitive transducers, such as capacitive micromachine ultrasonic transducers (CMUTs), Dry coupled ultrasonic (DCUT) transducer, and / or Electromagnetic Acoustic Transducer (EMAT) The probe device according to claim 11, comprising or having the same configuration.

13. The probe device according to claim 11 or 12, wherein the transducer configuration comprises or is in the form of one or more transducer arrays.

14. The probe device according to claim 13, wherein one or more of the transducer arrays comprises or are configured as phased array ultrasonic transducers (PAUTs).

15. The probe device according to any one of claims 1 to 14, wherein the intermediate member comprises or has the form of a wedge portion.

16. The probe device according to any one of claims 1 to 15, wherein the compliant element comprises or is in the form of a cylindrical or substantially cylindrical element.

17. The probe device according to any one of claims 1 to 16, wherein the probe device is configured such that the compliant element moves relative to the intermediate member.

18. The probe device according to claim 17, wherein the compliant element is configured to rotate around the intermediate member and / or the transducer configuration, and the compliant element comprises or is configured to comprise a rolling element, such as a tire or wheel.

19. The probe device according to any one of claims 1 to 18, wherein the compliant element defines at least a portion of the internal volume, and the transducer configuration and / or the intermediate member are arranged within the internal volume.

20. The probe device according to claim 19, wherein the probe device is configured such that the compliant element moves axially relative to the intermediate member, and the compliant element comprises or is in the form of a planar or substantially planar element, such as a membrane.

21. A probe device according to any one of claims 1 to 20, comprising a support structure.

22. The probe device according to claim 21, wherein the support configuration comprises or is in the form of a mandrel.

23. The probe device according to any one of claims 1 to 22, wherein the probe device is configured and / or operable to control the tilt angle of the compliant element to reduce deviations in the ultrasonic beam propagating within the subject.

24. A system for use in non-destructive evaluation of a subject, comprising one or more probe devices as described in any one of claims 1 to 23.

25. A method for non-destructive evaluation using a probe device according to any one of claims 1 to 23 or a system according to claim 24.

26. A probe device for use in non-destructive evaluation of a subject, A transducer configuration configured and / or operable to direct an ultrasonic beam toward the subject, A compliant element configured to engage with the subject and An intermediate member interposed between the transducer configuration and the compliant element Equipped with, The probe device is configured to control and / or be operable and / or operably associated with an arrangement for controlling the tilt angle of the compliant element in order to reduce deviations in the ultrasonic beam propagating within the subject.

27. The probe device according to claim 26, further comprising a passive configuration for controlling the inclination of the compliant element.

28. The probe device according to claim 27, wherein the passive configuration comprises one or more wheels.

29. The probe device according to claim 26, 27, or 28, wherein the probe device is coupled to and / or operably associated with an active configuration for controlling the inclination of the compliant element.

30. The probe device according to claim 29, wherein the active configuration comprises or is configured to control and / or operable actuator configuration for controlling the tilt of the compliant element.

31. A system for use in non-destructive evaluation of a subject, comprising one or more probe devices as described in any one of claims 26 to 30.

32. A method for non-destructive evaluation using a probe device according to any one of claims 26 to 30 or a system according to claim 31.

33. A probe device for use in non-destructive evaluation of a subject, wherein the probe device comprises or is in the form of a roller probe, The probe device comprises a transducer assembly having a transmit / receive split longitudinal wave (TRL) configuration or a similar configuration.

34. A probe device for use in non-destructive evaluation of a subject, The transducer configuration includes a transducer that is configured and / or operable to direct an ultrasonic beam toward the subject, The probe device comprises or is configured to include a roller probe. The transducer configuration is a probe device comprising or in the form of a matrix array.

35. A method for non-destructive evaluation of a subject, wherein the subject comprises or is in the form of a non-welded structure, and the method is The steps include: obtaining a plurality of signal sets, including a first signal set and a second signal set, by emitting ultrasound to the subject and receiving ultrasound returning from the subject; The steps include processing the first signal set and the second signal set to provide evaluation data related to the subject, and Includes, The first signal set includes a first sequence of first data elements over a first time period, each first data element including a first variable value for a variable and a first time value for the first variable value, and the first time period includes a first time sub-period. The second signal set includes a second sequence of second data elements over a second time period, each second data element including a second variable value for the variable and a second time value for the second variable value, and the second time period includes a second time sub-period. The first time subperiod and the second time subperiod include the same time value, The processing of the first signal set and the second signal set involves determining a modified signal set that contributes to the evaluation data. The aforementioned correction signal set is: The modified time sub-period includes the same time values ​​as the first time sub-period and the second time sub-period, and, with respect to the time values, the first variable value and the second variable value are in a given relationship with respect to the time values, and / or, the expression of the first variable value with respect to the time values ​​and the expression of the second variable value with respect to the time values. A method that, with respect to a time value, includes either an expression of the first variable value or an expression of the second variable value with respect to the time value, if the first variable value and the second variable value are not in a given relationship with respect to the time value.

36. We provide probe equipment, The method according to claim 35, comprising a preliminary step of positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

37. The method according to claim 35 or 36, wherein the subject comprises or is in the form of an object constructed using additive manufacturing technology.

38. The method according to claim 37, wherein the subject comprises or is in the form of an object constructed using metal additive manufacturing.

39. The method according to claim 38, wherein the subject comprises or is in the form of an object constructed using wire arc additive manufacturing (WAAM).

40. The method according to claim 35 or 36, wherein the subject comprises or is in the form of a composite material.

41. The method according to claim 35 or 36, wherein the subject includes or is in the form of a human or animal body.

42. The method according to any one of claims 35 to 41, wherein the first variable value is an expression of amplitude.

43. The method according to any one of claims 35 to 42, wherein the second variable value is an expression of amplitude.

44. The method according to any one of claims 35 to 43, wherein the first time period, the second time period, and / or one or more further time periods are of the same duration.

45. A method for non-destructive evaluation of a subject, The subject of the experiment comprises or is in the form of a non-welded structure. The aforementioned method, A step of performing an evaluation, comprising the step of providing the subject to a temperature above ambient temperature by heating during the evaluation, Performing the aforementioned evaluation means Radiating ultrasound into the volume of the subject, Receiving at least a portion of the ultrasound returning from the subject, thereby obtaining multiple signal sets, and To provide evaluation data related to the subject, one or more of the plurality of signal sets are processed. A method comprising, wherein the process includes a correction for the temperature within the volume of the subject at the rising temperature.

46. We provide probe equipment, The method according to claim 45, further comprising the preliminary step of positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

47. The method according to claim 45 or 46, wherein the subject comprises or is in the form of an object constructed using additive manufacturing technology.

48. The method according to claim 47, wherein the subject comprises or is in the form of an object constructed using metal additive manufacturing.

49. The method according to claim 48, wherein the subject comprises or is in the form of an object constructed using wire arc additive manufacturing (WAAM).

50. The method according to claim 45 or 46, wherein the subject comprises or is in the form of a composite material.

51. The method according to any one of claims 45 to 50, wherein the method includes a consistent temperature increase over the entire subject and / or a temperature increase including the temperature distribution in the subject and / or probe device.

52. The method according to claim 51, wherein the process includes a correction of the temperature distribution within the volume of the subject at the heating temperature.

53. The method according to claim 52, wherein the correction is corrected so that at least a portion of the path of the ultrasound through the volume of the probe device and / or the subject is corrected to give a corrected path.

54. A method for non-destructive evaluation of a subject, The subject of the experiment comprises or is in the form of a non-welded structure. The method includes the step of providing an ultrasonic probe, The aforementioned ultrasonic probe is Axial element and, An ultrasonic radiation transducer attached to the axial element, Two or more support elements rotatably mounted with respect to the axial element, A compliant element that is attached to two or more of the aforementioned support elements and provides a continuous surface in at least one direction. Equipped with, The two or more support elements and the compliant element define at least partially the internal volume of the probe, and the transducer is provided within the internal volume. The probe further comprises an inlet for a coolant into the internal volume and an outlet for a coolant out of the internal volume. The aforementioned method, The steps include: positioning at least a portion of the compliant element in contact with the subject; The steps include passing ultrasonic waves from the transducer to the subject and detecting reflected ultrasonic waves from the substrate. It further includes, A method comprising supplying a coolant to the internal volume through a coolant inlet and removing the coolant from the internal volume during the passage of the ultrasonic waves.

55. We provide probe equipment, The method according to claim 54, further comprising the preliminary step of positioning the probe device relative to a subject so that the probe device can emit ultrasound to the subject and receive ultrasound returning from the subject.

56. The method according to claim 54 or 55, wherein the subject comprises or is in the form of an object constructed using additive manufacturing technology.

57. The method according to claim 56, wherein the subject comprises or is in the form of an object constructed using metal additive manufacturing.

58. The method according to claim 57, wherein the subject comprises or is in the form of an object constructed using wire arc additive manufacturing (WAAM).

59. The method according to claim 54 or 55, wherein the subject comprises or is in the form of a composite material.

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