Component imaging system, component imaging device, and component imaging method

Abstract

To provide component imaging systems, component imaging apparatus, and component imaging methods.SOLUTION: A system (100) for imaging a component (102) defining a negative space (108) is provided comprising a component imaging assembly (104), a bolus insert (106), and an imaging device (114). The bolus insert is positionable in the negative space of the component when the component is positioned within an imaging field (120) to produce a component image (122). A method is provided comprising a step (506) of positioning a bolus insert within a negative space of a component, and a step (510) of scanning the component having the bolus insert to create an image of the component.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] Federally funded research This invention was made with Government support under Grant No. W58RGZ-19-C-0003 from the United States Army. The United States Government may have certain rights in this invention.

[0002] The present subject matter relates generally to imaging of components, and more particularly to internal imaging of components using image scanning. [Background technology]

[0003] Internal imaging or radiographic testing of components, such as gas turbine engine components, such as airfoils, shrouds, etc., results in a scan with image data indicative of the relative density of the material. Variations in material density shown in the component scan image can aid in identifying defects, measuring internal passages or cavities, etc. Some geometric features of the component may introduce artifacts in the image data that may give the appearance of density variations in the component that are not actually present, resulting in an erroneous conclusion that the component has one or more defects, or may inaccurately indicate the size and / or location of internal component features. In the case of radiographic imaging, these artifacts may be caused by scattering, beam hardening, and / or partial volume effects in the x-ray beam and interactions between the x-ray beam and the component. Therefore, improved imaging devices and imaging methods that reduce image artifact effects are desirable. Summary of the Invention [Means for solving the problem]

[0004] Aspects and advantages of the present disclosure will be set forth in part in the description which follows, or may be obvious from the description, or may be learned through practice of the subject matter of the present disclosure.

[0005] In one embodiment of the present subject matter, a system for imaging a component is provided, the component defining a negative space, the system comprising a component imaging assembly, a bolus insert, and an imaging device, the bolus insert being positionable within the negative space of the component when the component is positioned within an imaging field of the imaging device to generate an image of the component.

[0006] In another embodiment of the present subject matter, a method is provided that includes positioning a bolus insert within a negative space defined by a component and scanning the component with the bolus insert to generate an image of the component.

[0007] In a further embodiment of the present subject matter, a component imaging assembly is provided. The component imaging assembly includes a component including a first portion having a first thickness and a second portion having a second thickness. The first thickness is greater than the second thickness. Additionally, the component imaging assembly includes a bolus insert positioned adjacent to the second portion. The bolus insert has a bolus thickness that is substantially similar to the difference between the first thickness and the second thickness. The bolus insert has a bolus material density within fifteen percent (15%) of the component material density of the component.

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the subject matter of the present disclosure and, together with the following detailed description, serve to explain the principles of the disclosure.

[0009] A full and enabling disclosure of the present disclosure, including the best mode disclosed to one of ordinary skill in the art, is set forth in this specification, which makes reference to the accompanying figures. [Brief description of the drawings]

[0010] [Figure 1] 1 is a schematic cross-sectional view of a gas turbine engine in accordance with various embodiments of the present subject matter. [Diagram 2] 2 is a schematic diagram of a system including a component, such as a component of the gas turbine engine of FIG. 1, and a component imaging assembly, according to one embodiment of the present subject matter. [Diagram 3] 13 is an image of a component taken without a bolus insert. [Figure 4] 1 is an image of a component taken with a bolus insert, according to one embodiment of the present subject matter. [Diagram 5] 1 is a flow diagram illustrating a method for generating component images, according to one embodiment of the present subject matter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Reference will now be made in detail to the embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. This detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in these drawings and descriptions are used to refer to like or similar parts of the present disclosure.

[0012] As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to imply the position or importance of each component.

[0013] The terms "forward" and "rearward" refer to relative locations within a gas turbine engine or vehicle and are referenced to the normal operating position of the gas turbine engine or vehicle. For example, with respect to a gas turbine engine, forward refers to a location closer to the engine inlet and aft refers to a location closer to the engine outlet or exhaust.

[0014] The terms "upstream" and "downstream" refer to relative directions with respect to fluid flow within a fluid passageway. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows.

[0015] Terms such as "coupled," "fixed," and "mounted" refer to both direct coupling, fastening, or mounting, and indirect coupling, fastening, or mounting through one or more intermediate components or features, unless otherwise specified in this specification.

[0016] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0017] Approximate expressions as used throughout this specification and claims are used to modify any quantitative expression that may vary permissibly without affecting its associated basic function. Thus, a numerical value modified by terms such as "about", "approximately", and "substantially" is not limited to the exact numerical value specified. In at least some instances, the approximate expression may correspond to the precision of an instrument for measuring the numerical value, or to the precision of a method or machine for making or manufacturing a component and / or system. Approximate expressions may indicate a tolerance of + / - 1, 2, 4, 10, 15, or 20 percent for any of the individual numerical values, numerical ranges, and / or endpoints defining the numerical range.

[0018] In this section and throughout the specification and claims, unless otherwise indicated by context or expression, range limits are combined and substituted for one another to include all subranges within which a range is specified. For example, all ranges disclosed herein are inclusive of their endpoints, and the endpoints are freely combinable with one another.

[0019] Generally, the present subject matter provides systems and methods for improving component imaging. For example, a system as described herein includes a component imaging assembly including a component defining a negative space and a bolus insert positioned within the negative space. The system further includes an imaging device, where the component is positioned within an imaging field of the imaging device to generate an image of the component. The bolus insert, which may be shaped to at least partially complement the negative space to normalize or adjust the component geometry and may have a density approximating the component density, helps reduce or eliminate image artifacts caused by scattering, beam hardening, and / or partial volume effects, such as by normalizing the beam path distance for all figures or all captured projections. Furthermore, the systems and methods described herein are capable of generating image data with stable signal-to-noise ratio, contrast, and resolution even when the component geometry is irregular.

[0020] Referring now to the drawings, where like numerals refer to like elements throughout, Figure 1 is a schematic cross-sectional view of a gas turbine engine in accordance with one embodiment of the present disclosure. For the embodiment of Figure 1, the gas turbine engine is a high bypass turbofan jet engine, referred to herein as "turbofan engine 10." As shown in Figure 1, the turbofan engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12, which is provided for reference) and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream from the fan section 14.

[0021] The illustrated core turbine engine 16 generally includes a substantially tubular outer casing 18 defining an annular inlet 20. The outer casing 18 encloses in serial flow relationship a compressor section including a booster or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24, a combustion section 26, a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30, and a jet outlet section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0022] For the embodiment shown, the fan section 14 includes a fan 38 having a plurality of fan blades 40 coupled in spaced relation to a disk 42. As shown, the fan blades 40 extend outwardly from the disk 42 along a generally radial direction R. The fan blades 40 and disk 42 are rotatable together about a longitudinal axis (illustrated as longitudinal centerline 12) by an LP shaft or spool 36. In some embodiments, a power gearbox having a plurality of gears may be included to reduce the rotational speed of the LP shaft or spool 36 to a more efficient rotational fan speed.

[0023] 1 embodiment, the disk 42 is covered by a rotatable forward nacelle 48 that is aerodynamically contoured to facilitate airflow past the plurality of fan blades 40. Additionally, the fan section 14 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the core turbine engine 16. It should be appreciated that the nacelle 50 may be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced exhaust outlet guide vanes 52. Additionally, a downstream section 54 of the nacelle 50 may extend over an outer portion of the core turbine engine 16 to define a bypass airflow passage 56 between the downstream section 54 and the outer portion.

[0024] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through an associated air inlet 60 of the nacelle 50 and / or fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is channeled into the bypass airflow passage 56 and a second portion of the air 58, as indicated by arrow 64, is channeled into the LP compressor 22. The ratio of the first portion of air 62 to the second portion of air 64 is commonly known as the bypass ratio. The pressure of the second portion of air 64 is then increased by being channeled through the high pressure (HP) compressor 24 and into the combustion section 26 where it is mixed with fuel and combusted to generate combustion gases 66.

[0025] The combustion gases 66 are routed through the HP turbine 28 where a portion of thermal and / or kinetic energy is extracted from the combustion gases 66 via a series of stages of HP turbine vanes 68 coupled to the outer casing 18 and HP turbine blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 and thereby assisting in the operation of the HP compressor 24. The combustion gases 66 are then routed through the LP turbine 30 where a second portion of thermal and kinetic energy is extracted from the combustion gases 66 via a series of stages of LP turbine vanes 72 coupled to the outer casing 18 and LP turbine blades 74 coupled to the LP shaft or spool 36, thereby rotating the LP shaft or spool 36 and thereby assisting in the operation of the LP compressor 22 and / or the rotation of the fan 38.

[0026] The combustion gases 66 are then channeled through the jet outlet section 32 of the core turbine engine 16 to generate thrust. At the same time, the pressure of the first air portion 62 is significantly increased as the first air portion 62 is channeled through the bypass airflow passage 56, and the first air portion 62 is then exhausted from a fan outlet section 76 of the turbofan engine 10 to also generate thrust. The HP turbine 28, the LP turbine 30, and the jet outlet section 32 at least partially define a hot gas path 78 for channeling the combustion gases 66 through the core turbine engine 16.

[0027] Turning now to FIG. 2, a system 100 is illustrated in accordance with various embodiments of the present subject matter. As described herein, the system 100 is used to image a component 102, such as a component of a turbofan engine 10, such as a fan blade 40, turbine vanes 68, 72, turbine rotor blades 70, 74, turbine shroud, etc. The system includes a component imaging assembly 104 for imaging the component 102 using a bolus insert 106. More specifically, the component 102 defines a negative space 108, such as a groove, lip, flange, or passage, such that at least a portion of the component 102 is thinner than other portions of the component 102. That is, a first portion 110 has a first thickness t1 (FIGS. 3, 4) and a second portion 112 has a different second thickness t2 (FIGS. 3, 4), where the first thickness t1 is greater than the second thickness t2 or the second thickness t2 is less than the first thickness t1. The bolus insert 106 is positioned within the negative space 108 to increase the thickness of the second portion 112 such that the component imaging assembly 104 has a substantially uniform cross-sectional thickness. In at least some embodiments, the bolus insert 106 increases the thickness of the second portion 112 by substantially filling the negative space 108, thereby increasing the thickness of the second portion 112 to make the thickness of the second portion 112 substantially equivalent to the thickness of the first portion 110, thereby increasing the thickness of the second portion 112 to a value substantially similar to the difference between the second thickness t2 and the first thickness t1. b (Figure 4).

[0028] 2-4 depict a component 102 with a negative space 108 defined by only two component thicknesses t1 and t2, it will be understood that the present disclosure may also apply to a component 102 having a negative space 108 defined by three or more thicknesses. For example, the negative space 108 may be defined by a curved surface or the like, in which case the thickness of the component 102 varies from one location to another along a length such that the component 102 and the bolus insert 106 positioned adjacent the component surface each have a plurality of thicknesses. However, for any two component thicknesses t1, t2 among the plurality of component thicknesses adjacent which the bolus insert 106 is positioned, the bolus insert 106 may have a thickness t1 that may be substantially similar to the difference between the two component thicknesses t1, t2 such that the bolus insert 106 substantially fills the negative space 108 defined by the component surface between the locations along the component surface having a first thickness t1 and a second thickness t2. b It will be understood that the

[0029] The system 100 also includes an imaging device 114. For example, the imaging device 114 is a radiological imaging device, such as a digital radiography (DR) machine, a film radiography machine, or a computed tomography (CT) scanner. In some embodiments, the radiological imaging device 114 includes a radiological imaging source 116 and a radiological imaging receiver 118, such as a detector or film. The component 102 is positioned within an imaging field 120 of the imaging device 114 to generate an image 122 (FIGS. 3, 4) of the component 102. The image 122 is a representation of the interior of the component 102, which may aid in measurements at or near internal features, such as internal passages or cavities, and / or may aid in identifying defects in the component material, such as cracks, fissures, unintended holes or apertures, and / or other types of weak spots in the component material.

[0030] The bolus insert 106 disposed within the negative space 108 helps to reduce or eliminate image artifacts that may falsely suggest the presence of openings, cracks, gaps, apertures, etc. in the material forming the component 102. More specifically, some geometric features of the component 102, such as the flange 124 defined around the edge of the ring-shaped component 102 shown in FIG. 2, can cause artifacts in the image data that give the appearance of density variations in the component 102 (such density variations generally suggesting openings, cracks, etc., e.g., defects, in the component 102) when in fact no such density variations are present. The flange 124 defines the negative space 108, and the bolus insert 106 positioned within the negative space 108 reduces or eliminates the effect of the negative space 108 by "tuning" the component geometry or increasing the thickness of the component 102 in the region of the flange 124 such that the component 102 appears to the imaging device 114 to have a uniform geometry or thickness. This results in uniform component geometry and component thickness, thereby mitigating image artifacts that may be perceived as a reduction or change in signal from the imaging device (e.g., a reduction in CT signal if the imaging device 114 is a CT scanner) that may be confused with openings, gaps, cracks, etc. in the component material.

[0031] Thus, the bolus insert 106 has a shape or geometry that at least partially complements the negative space 108 and a density that approximates the density of the component 102. The negative space 108 has a geometry that may be referred to as the spatial geometry defined by the component 102. The bolus insert 106 has a bolus geometry that at least partially complements the spatial geometry. In at least some embodiments, the bolus geometry of the bolus insert 106 is such that the bolus insert 106 fits closely to the component 102 within the negative space 108, e.g., closely approximating the component material in the absence of the negative space 108. For example, as shown in FIG. 2, the flange 124 of the component 102 may have an annular or ring shape such that the negative space 108 has an annular or ring shape. In such an embodiment, the bolus insert 106 has a complementary annular or ring shape that fills the negative space 108, e.g., such that the negative space 108 does not appear to exist to the imaging device 114. The bolus insert 106 may be sized and shaped to minimize or eliminate a gap between the bolus insert 106 and the component 102. Thus, in the illustrated embodiment, the bolus insert 106 is shaped and sized to minimize or eliminate a negative space 108 defined by the flange 124. It will be appreciated that the bolus insert 106 may be shaped to conform to a particular negative space 108, and thus one or more bolus inserts 106 may be manufactured for a single component 102, and / or different bolus inserts 106 may be manufactured for different components 102, e.g., each bolus insert 106 conforming to the geometry of a respective negative space 108. It will further be appreciated that the bolus insert 106 need not be shaped only to the component 102 and the negative space 108.For example, the bolus insert 106 may be shaped to complement a beam path, such as the beam path from the radiographic imaging source 116 to optimize the beam path through the component 102 .

[0032] Further, the component 102 is formed from a component material having a component material density. Similarly, the bolus insert 106 is formed from a bolus material having a bolus material density. To maximize the benefits of the bolus insert 106, the bolus material density should be as close as possible to the component material density, i.e., the bolus material should be within the density tolerance of the component material. For example, in some embodiments, the bolus material density is within fifteen percent (15%) of the component material density, i.e., the bolus material density is ±15% of the component material density. More specifically, the bolus material density is within ten percent (10%) of the component material density, i.e., the bolus material density is ±10% of the component material density. Furthermore, the bolus material density is within five percent (5%) of the component material density, i.e., the bolus material density is ±5% of the component material density. Having the bolus density substantially close to or equal to the component density aids in equalizing path lengths (e.g., for DR imaging) or projections (for CT imaging), thereby improving image quality, such as by reducing image artifacts. It will be appreciated that the bolus material and bolus material density may be matched to a particular component 102 and its component material density, as well as the geometry of the bolus insert 106, such that the bolus material density may vary for each bolus insert 106, such as when the component material and its component material density differ for each component 102 in which the bolus insert 106 is used.

[0033] As shown in FIG. 2, the component 102 is angled relative to the radiographic imaging source 116 and the radiographic imaging receiver 118 (e.g., a detector or film). In the embodiment of FIG. 2, the component 102 is angled upward relative to the radiographic imaging source 116 such that a proximal end 126 of the component 102 closest to the radiographic imaging source 116 is positioned higher than a distal end 128 of the component 102 closest to the radiographic imaging receiver 118. In other embodiments, the component 102 may be angled downward or in other directions relative to the radiographic imaging source 116. The illustrated component 102 is at an angle α with respect to the horizontal direction H, i.e., angle α is the angle measured from the horizontal direction H to a surface 130 of the component 102 facing the horizontal direction H. It will be understood that the horizontal direction H is perpendicular to the vertical direction V.

[0034] The angle α of the component 102 relative to the radiographic imaging source 116 and / or radiographic imaging receiver 118 may be optimized based on, for example, the configuration or design of the bolus insert 106 to ensure optimal image quality. More specifically, for a given configuration of the bolus insert 106, the angle α of the component 102 may be selected to minimize image noise, as well as scattering, beam hardening, and / or partial volume effects that may otherwise result from interactions between the beam from the radiographic imaging source 116 and the component 102. In some embodiments, the angle α may be in the range of about 0° to about 90° relative to the horizontal direction H. As described herein, the bolus insert 106 has a shape that thickens thinner regions of the component 102 to eliminate spatial non-stationarity of relative image metrics, taking into account the angle α at which the component 102 with the bolus insert 106 is placed relative to the radiographic imaging source 116 and radiographic imaging receiver 118 of the scanner or imaging device 114.

[0035] Additionally, the component 102 may be rotated about an axis A extending along the vertical direction V, as suggested by the arrow 132 indicating the direction of rotation, to change the position of the component 102 for successive images. That is, the position of the component 102 may be changed for each image captured by the imaging device 114, e.g., such that the proximal end 126 of the component 102 is in a different position for each image captured by the imaging device 114, and each portion of the component 102 is in a different position relative to the radiographic imaging source 116. The component 102 may be rotated to generate a complete 360° image of the component 102. It will be appreciated that the component 102 may be rotated manually or automatically, e.g., the component 102 may be supported by one or more operators to manually reposition the component 102 for each image capture, or the component 102 may be supported by an automated machine to reposition the component 102 for each image capture. As described herein, the bolus insert 106 may extend into the entire negative space 108, or may extend into only a portion of the negative space 108. In embodiments in which the bolus insert 106 extends into only a portion of the negative space 108, the bolus insert 106 can be repositioned as the component 102 is repositioned or rotated so that the bolus insert 106 is always located within the negative space 108 at or near the proximal end 126 of the component 102 to help mitigate or eliminate data artifacts that might otherwise be caused by the negative space 108.

[0036] As previously mentioned, in some embodiments, such as the embodiment shown in Figure 2, the component 102 has an annular or ring shape and is formed from a component material. For example, the component 102 may be a ring shroud of the turbofan engine 10 formed from a ceramic matrix composite material (CMC). In various embodiments, the CMC material may include silicon carbide (SiC), silicon, silica, carbon, or alumina matrix materials, and combinations thereof. Ceramic fibers may be embedded within this matrix, such as oxidatively stable reinforcing fibers including monofilaments such as sapphire and silicon carbide (e.g., SCS-6 from Textron), as well as rovings and yarns including silicon carbide (e.g., NICALON® from Nippon Carbon, TYRANNO® from Ube Industries, and SYLRAMIC® from Dow Corning), rovings and yarns including aluminosilicates (e.g., Nextel 440 and Nextel 480 from 3M), and rovings and yarns including chopped whiskers and staple fibers (e.g., Nextel 440 and SAFFIL® from 3M), and optionally these oxidatively stable reinforcing fibers including ceramic particles (e.g., Si oxide, Al oxide, Zr oxide, Y oxide, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite). For example, in some embodiments, fiber bundles that may include a ceramic refractory material coating are formed as a reinforcing tape, such as a unidirectional reinforcing tape. A plurality of these tapes may be laid up together (e.g., as a pile) to form a preform component. These fiber bundles may be impregnated with a slurry composition before or after the formation of the preform. The preform may then undergo a heat treatment, such as curing or burning to provide high char retention in the preform, followed by a chemical treatment, such as melt infiltration with silicon, to achieve a component formed from a CMC material with a desired chemical composition. In other embodiments, the CMC material may be formed, for example, as a carbon fiber cloth rather than as a tape.

[0037] As previously mentioned, the bolus insert 106 is shaped to complement the negative space 108 defined by the component 102. In the embodiment shown in FIG. 2, the negative space 108 has a ring shape and extends around the radially outer edge 134 of the component 102. Thus, in some embodiments, the bolus insert 106 may be a bolus material ring that extends around the entire radially outer edge 134, i.e., extends around the periphery of the component 102 corresponding to the negative space 108 shown in FIG. 2. In other embodiments, the bolus insert 106 may be a bolus material arc, i.e., a partial ring of bolus material that extends around a portion of the radially outer edge 134 of the component 102 as shown in FIG. 2, in which case the bolus insert 106 does not fill all of the negative space 108 (does not correspond to the negative space 108). More specifically, the arc-shaped bolus insert 106 extends across an arc having an angular distance such that the arc extends across less than a full 360° of the annular negative space 108.

[0038] Further, as previously mentioned, the bolus insert 106 is formed from a bolus material that is similar in density to the component material forming the component 102. In embodiments where the component material is a CMC material, the bolus material may be, for example, aluminum, which has a density that is similar or comparable to that of a typical CMC material. Thus, in at least some embodiments, such as that shown in FIG. 2, the bolus insert 106 may be an arc-shaped insert formed from aluminum. As further shown in the embodiment of FIG. 2, the proximal end 126 of the component 102 on which the arc-shaped bolus insert 106 is positioned is at an angle α of about 30° relative to the horizontal direction H when positioned between the radiographic imaging source 116 and the radiographic imaging receiver 118. Furthermore, as described above, the component 102 may be repositioned for each image capture, and the arc-shaped bolus insert 106 is moved as the component 102 is rotated about the vertical direction V such that the bolus insert 106 is always positioned at the proximal end 126 of the component 102.

[0039] 3 and 4, the effect of the aluminum bolus insert 106 on the imaging of the CMC ring shroud component 102 as described herein can be seen by comparing two images 122 of the CMC ring shroud component 102 acquired using CT imaging. FIG. 3 shows an image 122 of the CMC ring shroud component 102 without the bolus insert 106, and FIG. 4 shows an image 122 of the CMC ring shroud component 102 with the bolus insert 106. By specifically comparing the area indicated by the arrow 136 in each image, it can be seen that the CT image captured with the bolus insert 106 significantly reduces image artifacts in the area of ​​the flange 124 that defines the negative space 108. That is, in the area of ​​the negative space 108 where the thickness of the component 102 (i.e., the thickness of the flange 124) is less than the thickness of the remainder of the component 102, image artifacts are present in the image of FIG. 3 (without the bolus insert 106) but are nearly absent in the image of FIG. 4 (with the bolus insert 106). It can thus be seen that the bolus insert 106 helps reduce, and in some instances may completely eliminate, image artifacts caused by scattering, beam hardening, and / or partial volume effects. As previously discussed, reducing image artifacts may improve component inspection for detection and / or metrology purposes, for example, by preventing false identification of component defects, improving metrology of component features, etc.

[0040] It will be understood that the ring shroud component 102 formed from a CMC material and the arc-shaped bolus insert 106 formed from aluminum are presented as examples only. That is, the component 102 may be any component, device, or object having a negative space 108 formed from essentially any material and not limited to a ring shape. As some examples, the component 102 may be a metal compressor or turbine blade of the turbofan engine 10, or the component 102 may be a non-metallic object that is not part of, not used with, or otherwise unrelated to a gas turbine engine, such as an automotive component, a household appliance, a medical device or implant, to name a few. As described herein, the bolus insert 106 has a geometry that at least partially complements the negative space of the component 102, and thus is not limited to an arc or ring shape. Furthermore, the bolus insert 106 may have a density substantially similar to that of the component 102, and thus may be any suitable material having a substantially similar density (e.g., a metallic material, a non-metallic material, etc.). Of course, factors such as cost, availability, machinability, etc. may be further considered in selecting the bolus material, so long as the density of the selected bolus material is substantially similar to the density of the component materials.

[0041] 5, a flow diagram of a method according to an embodiment of the present disclosure is presented. The illustrated method 500 includes selecting (502) a bolus material for a bolus insert 106 to be positioned within a component 102 formed from the component material. The bolus material has a bolus density within a density tolerance of the component material, such as within about 5%, 10%, or 15% of the density of the component material, such that the bolus density is substantially close to or equal to the component density. Additionally, the method 500 includes shaping (504) the bolus insert 106 to conform to a negative space 108 defined by the component 102. As described herein, shaping the bolus insert 106 may include forming, machining, or otherwise shaping the bolus material such that the bolus material has a shape that complements the shape of the negative space 108. The method 500 also includes positioning (506) the bolus insert 106 in the negative space 108 of the component 102, and disposing (508) the component 102 having the bolus insert 106 between the radiographic imaging source 116 and the radiographic imaging receiver 118. As described herein, the imaging device 114 including the radiographic imaging source 116 and the radiographic imaging receiver 118 may be a digital radiography (DR) device, a film radiography device, a computed tomography (CT) device, or the like, and the component 102 having the bolus insert 106 may be angled relative to the radiographic imaging source 116 and the radiographic imaging receiver 118 as described herein.

[0042] 5, the method 500 further includes scanning (510) the component 102 having the bolus insert 106 to generate an image of the component 102. An example of such an image is shown in FIG. 4, which shows a cross-section of a ring shroud component 102 with the bolus insert 106 positioned adjacent to the flange 124 to equalize the thickness of the component 102 in the area of ​​the flange 124 with the thickness of other portions of the component 102. In some embodiments, scanning the component 102 includes sending an x-ray beam from a radiographic imaging source 116 to the component 102 having the bolus insert 106. In other embodiments, a different imaging device 114 utilizing a different imaging technique may be used.

[0043] Thus, as described herein, the subject matter provides systems and techniques for reducing image artifact effects in component imaging or component scan images. More specifically, a bolus or bolus insert is used to adjust and reduce the effect of variations in component geometry or component thickness. Bolus inserts can be provided for a variety of components formed from any material with irregular geometry. The bolus insert is manufactured to have the same or similar density as the component, so that the imaging source (e.g., x-ray) interacts similarly with both the bolus insert and the component. More importantly, the bolus insert is manufactured to match the surface of the component and the bolus insert thickness is optimized, for example, so that the combination of x-ray path lengths through the component and the bolus is normalized, thereby reducing artifacts caused by the geometry of the component. Furthermore, image quality metrics that would otherwise have spatial non-stationarity, such as contrast, noise, and resolution in thick regions of the component compared to thin regions, are also normalized, resulting in more intuitive radiographic imaging data. Thus, the acquired component data can be further easily evaluated by a human operator or computer-aided evaluation software.

[0044] The use of the bolus insert can improve inspection for defect detection or metrology purposes, which can improve component quality, such as by accurately identifying component defects. As described herein, the bolus insert for component imaging can improve image evaluation, thereby reducing the need for queries and judgments by the operator performing the image evaluation, and can improve gauge repeatability and gauge reproducibility. Additionally, the bolus insert in the component can improve scan time by not requiring additional scans for the component to mitigate image artifacts. Thus, the bolus insert can improve cycle time and inspection costs. Additionally, the use of the bolus insert with the component in component imaging can improve porosity detection and / or discontinuity suggestion detection. Additionally or alternatively, the bolus insert can enable advanced radiological diagnostics and CT / DR internal metrology.

[0045] Thus, by placing an optimally manufactured bolus insert on the component, the interaction of the imaging source (e.g., x-ray beam) with the irregular geometry of the component can be optimized and image artifact effects can be eliminated, thereby improving inspection for component defect detection, metrology, and evaluation. More specifically, by using a bolus insert on the component, a stable signal is captured at the imaging receiver or detector (e.g., x-ray detector). This stable signal results in image data that more closely approximates the relative density of the component material being imaged. By using this technique, image artifacts caused by scattering, beam hardening, and / or partial volume effects can be reduced or eliminated. Furthermore, this technique can generate image data with stable signal-to-noise ratio, contrast, and resolution within irregular component geometries that may otherwise exhibit these problems and make the data difficult to interpret. Additionally, other advantages of the subject matter described herein will be appreciated by those skilled in the art.

[0046] Further aspects of the present disclosure are provided by the subject matter of the following sections.

[0047] 1. A system for imaging a component defining a negative space, comprising a component imaging assembly, a bolus insert, and an imaging device, the bolus insert being positionable within the negative space of the component when the component is positioned within an imaging field of the imaging device to generate an image of the component.

[0048] 2. The system of any preceding paragraph, wherein the negative space has a spatial geometry and the bolus insert has a bolus geometry that at least partially complements the spatial geometry.

[0049] 3. The system of any preceding paragraph, wherein the component is formed from a component material having a component material density and the bolus insert is formed from a bolus material having a bolus material density, the bolus material density being within fifteen percent (15%) of the component material density.

[0050] 4. The system of any preceding paragraph, wherein the bolus material density is within ten percent (10%) of the component material density.

[0051] 5. The system of any preceding paragraph, wherein the imaging device is a radiological imaging device.

[0052] 6. The system of any preceding paragraph, wherein the radiation imaging device comprises a radiation imaging source and a radiation imaging receiver.

[0053] 7. The system of any preceding paragraph, wherein the component is angled relative to the radiation imaging source.

[0054] 8. A system of any preceding paragraph, wherein the component is positioned at an angle α to the horizontal which is perpendicular to the vertical.

[0055] 9. The system of any preceding paragraph, wherein the component is rotatable about an axis extending along the vertical direction to reposition the component within the imaging field.

[0056] 10. The system of any preceding paragraph, wherein the component has a first thickness in a first portion and a second thickness in a second portion adjacent the negative space, the second thickness being less than the first thickness, and the bolus insert has a bolus thickness to fill the difference between the second thickness and the first thickness within the negative space.

[0057] 11. The system of any preceding paragraph, wherein the component is a ring shroud of a gas turbine engine, the ring shroud having a flange extending around a radially outer edge and defining a negative space, the negative space being annular.

[0058] 12. The system of any preceding paragraph, wherein the bolus insert has an arc shape.

[0059] 13. The system of any preceding paragraph, wherein the component comprises a ceramic matrix composite (CMC).

[0060] 14. The system of any preceding paragraph, wherein the bolus insert is formed from aluminum.

[0061] 15. A method comprising positioning a bolus insert within a negative space defined by a component, and scanning the component with the bolus insert to generate an image of the component.

[0062] 16. The method of any preceding paragraph, further comprising disposing a component having a bolus insert between the radiographic imaging source and the radiographic imaging receiver.

[0063] 17. The method of any preceding paragraph, wherein scanning the component includes transmitting an x-ray beam from a radiographic imaging source to the component.

[0064] 18. The method of any preceding paragraph, further comprising the step of shaping the bolus insert to conform to the negative space of the component.

[0065] 19. The method of any preceding paragraph, further comprising the step of selecting a bolus material for the bolus insert.

[0066] 20. The method of any preceding paragraph, wherein the bolus material has a bolus material density that is within fifteen percent (15%) of a component material density of the component materials forming the component.

[0067] 21. The method of any preceding paragraph, wherein scanning the component comprises using a digital radiography imaging device to image the component.

[0068] 22. The method of any preceding paragraph, wherein the step of scanning the component includes using a film radiography imaging device to image the component.

[0069] 23. The method of any preceding paragraph, wherein scanning the component includes using a computed tomography imaging device to image the component.

[0070] 24. A component imaging assembly comprising: a component having a first portion having a first thickness and a second portion having a second thickness, the first thickness being greater than the second thickness; and a bolus insert positioned adjacent to the second portion, the bolus insert having a bolus thickness that is substantially similar to a difference between the first thickness and the second thickness, the bolus insert having a bolus material density within fifteen percent (15%) of a component material density of the component.

[0071] This detailed description of the invention uses examples to disclose preferred embodiments, including the best mode, and also to enable those skilled in the art to practice the subject matter, including making and using any devices or systems and practicing any incorporated methods. The patentable scope of the subject matter disclosed herein is defined by the scope of the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or equivalent structural elements that do not differ substantially from the literal language of the claims.

[0072] Further aspects of the present disclosure are provided by the subject matter of the following sections.

[0073] 1. A system for imaging a component defining a negative space, comprising a component imaging assembly, a bolus insert, and an imaging device, the bolus insert being positionable within the negative space of the component when the component is positioned within an imaging field of the imaging device to generate an image of the component.

[0074] 2. The system of any preceding paragraph, wherein the negative space has a spatial geometry and the bolus insert has a bolus geometry that at least partially complements the spatial geometry.

[0075] 3. The system of any preceding paragraph, wherein the component is formed from a component material having a component material density and the bolus insert is formed from a bolus material having a bolus material density, the bolus material density being within fifteen percent (15%) of the component material density.

[0076] 4. The system of any preceding paragraph, wherein the bolus material density is within ten percent (10%) of the component material density.

[0077] 5. The system of any preceding claim, wherein the imaging device is a radiological imaging device.

[0078] 6. The system of any preceding claim, wherein the radiation imaging device comprises a radiation imaging source and a radiation imaging receiver.

[0079] 7. The system of any preceding claim, wherein the component is angled relative to the radiation imaging source.

[0080] 8. The system of any preceding paragraph, wherein the component is positioned at an angle α with respect to a horizontal direction that is perpendicular to the vertical direction.

[0081] 9. A system according to any preceding paragraph, wherein the component is rotatable about an axis extending along the vertical direction to reposition the component within the imaging field.

[0082] 10. The system of any preceding paragraph, wherein the component has a first thickness in a first portion and a second thickness in a second portion adjacent the negative space, the second thickness being less than the first thickness, and the bolus insert has a bolus thickness to fill the difference between the second thickness and the first thickness within the negative space.

[0083] 11. The system of any preceding paragraph, wherein the component is a ring shroud of a gas turbine engine, the ring shroud having a flange extending around a radially outer edge and defining a negative space, the negative space being annular.

[0084] 12. The system of any preceding paragraph, wherein the bolus insert has an arc shape.

[0085] 13. The system of any preceding claim, wherein the component comprises a ceramic matrix composite (CMC).

[0086] 14. The system of any preceding paragraph, wherein the bolus insert is formed from aluminum.

[0087] 15. A method comprising positioning a bolus insert within a negative space defined by a component, and scanning the component with the bolus insert to generate an image of the component.

[0088] 16. The method of any preceding claim, further comprising disposing a component having a bolus insert between the radiographic imaging source and the radiographic imaging receiver.

[0089] 17. The method of any preceding claim, wherein scanning the component includes transmitting an x-ray beam from a radiographic imaging source to the component.

[0090] 18. The method of any preceding claim, further comprising shaping the bolus insert to conform to the negative space of the component.

[0091] 19. The method of any preceding paragraph, further comprising the step of selecting a bolus material for the bolus insert having a bolus material density that is within fifteen percent (15%) of a component material density of the component material forming the component.

[0092] 20. A component imaging assembly comprising: a component including a first portion having a first thickness and a second portion having a second thickness, the first thickness being greater than the second thickness; and a bolus insert positioned adjacent to the second portion, the bolus insert having a bolus thickness that is substantially similar to a difference between the first thickness and the second thickness, the bolus insert having a bolus material density within fifteen percent (15%) of a component material density of the component. [Explanation of symbols]

[0093] 10. Turbofan engine 12 Longitudinal axis, longitudinal centerline 14. Fan Section 16 Core Turbine Engine 18 Outer casing 20 Circular Entrance 22 Low pressure LP compressor 24 High Pressure Compressor 26 Combustion Section 28 High Pressure HP Turbine 30 Low pressure LP turbine 32 Jet Nozzle Section 34 Spool 36 Spool 38 Fans 40 Fan Blade 42 Discs 48 Rotatable forward nacelle 50 Outer nacelle 52 Exhaust port guide vane 54 Downstream Section 56 Bypass air passage 58 Air Volume, Air 60 Air Intake 62 First Air Section 64 Second Air Section 66 Combustion Gas 68 HP Turbine Vanes 70 HP Turbine Blades 72 LP turbine vane 74 LP turbine blades 76 Fan Outlet Section 78 Hot Gas Path 100 Systems 102 Components 104 Component Imaging Assembly 106 Bolus Insert 108 Negative Space 110 First Part 112 Second Part 114 Imaging Devices 116 Radiation Imaging Sources 118 Radiation Imaging Receiver 120 Imaging Field 122 images 124 Flange 126 Proximal end 128 Distal end 130 Surface 132 Rotation direction 134 Radial outer edge t1 First thickness t2 Second thickness

Claims

1. A system (100) for imaging a component (102), comprising: a component imaging assembly (104); A bolus insert (106); an imaging device (114); the bolus insert (106) is positionable within a negative space (108) defined by a varying thickness of the component (102); the bolus insert (106) has a shape that at least partially complements the negative space (108) of the component (102) such that the bolus insert (106) fits closely against the component (102) within the negative space (108) defined by the varying thickness of the component (102); the component (102) is formed from a component material having a component material density; the bolus insert (106) is formed from a bolus material having a bolus material density; the bolus material density is within fifteen percent (15%) of the component material density; A system (100), wherein the bolus insert (106) is sized to present the appearance of a uniform thickness of the component (102) to the imaging device (114) when the component (102) and the bolus insert (106) are positioned within an imaging field (120) of the imaging device (114) to generate an image (122) of the component (102).

2. The system (100) of claim 1, wherein the bolus material density is within ten percent (10%) of the component material density.

3. The system of claim 1 , wherein the imaging device is a radiological imaging device.

4. The system (100) of claim 3, wherein the radiation imaging device (114) comprises a radiation imaging source (116) and a radiation imaging receiver (118).

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

6. The system (100) of claim 1, wherein the component (102) is positioned at an angle α with respect to a horizontal direction (H) that is perpendicular to a vertical direction (V).

7. 7. The system (100) of claim 6, wherein the component (102) is rotatable about an axis (A) extending along the vertical direction (V) to reposition the component (102) within the imaging field (120).

8. the component (102) has a first thickness (t1) at a first portion (110) and a second thickness (t2) at a second portion (112) adjacent the negative space (108); The second thickness (t2) is less than the first thickness (t1); 2. The system (100) of claim 1, wherein the bolus insert (106) has a bolus thickness (tb) to fill a difference between the second thickness (t2) and the first thickness (t1) in the negative space (108).

9. The component (102) is a ring shroud for a gas turbine engine (10); the ring shroud having a flange (124) extending about a radially outer edge (134) and defining the negative space (108); The system (100) of claim 1, wherein the negative space (108) is annular.

10. The system of claim 9 , wherein the bolus insert has an arc shape.

11. The system (100) of claim 1, wherein the component (102) comprises a ceramic matrix composite (CMC).

12. The system (100) of claim 11, wherein the bolus insert (106) is formed from aluminum.

13. Positioning (506) a bolus insert (106) within a negative space (108) defined by the components (102), comprising: The component (102) has a varying thickness that defines the negative space (108); the component (102) is formed from a component material having a component material density; the bolus insert (106) is formed from a bolus material having a bolus material density; the bolus material density is within fifteen percent (15%) of the component material density; A method (500) comprising: a step (510) of scanning the component (102) having the bolus insert (106) to generate an image (122) of the component (102), the bolus insert (106) being sized to provide an appearance of uniform thickness of the component (102) in the image (122).

14. 14. The method of claim 13, further comprising repositioning the component (102) within an imaging field (120) and scanning to generate another image (122).

15. 14. The method of claim 13, further comprising the step of repositioning the bolus insert (106) within the negative space (108) defined by the component (102) and scanning to generate another image (122).

Images