Extended Coverage Localized Immersion for Non-Destructive Testing (NDT)

Abstract

The acoustic test probe assembly may include a multi-layer structure at or near the interface between the acoustic test probe assembly and the test sample. For example, a gasket or seal arrangement may be used to establish a closed couplant fill area between the membrane formed by the multi-layer structure and the test sample. Excess couplant may be collected around the periphery of the closed couplant fill area, such as by using a port or other feature through which suction may be applied to collect the couplant, for example, to provide immersion at the interface between the probed while reducing or minimizing loss of couplant.

Description

[Technical Field]

[0001] Priority claims This application claims priority to U.S. Provisional Patent Application No. 63 / 261,140, ​​filed September 13, 2021, which is incorporated herein by reference in its entirety, and the benefit of which priority is claimed herein.

[0002] This document relates generally, but not exclusively, to non-destructive evaluation, and more particularly to apparatus and techniques for providing acoustic inspection, such as using a fluid immersion device integrated on or within a test probe assembly. [Background technology]

[0003] Various inspection techniques can be used to image or otherwise analyze structures without damaging such structures. For example, one or more of x-ray inspection, eddy current inspection, or acoustic (e.g., ultrasound) inspection can be used to acquire data for imaging features on or within a test sample. For example, acoustic imaging can be performed using an array of ultrasonic transducer elements, such as to image a region of interest within the test sample. Different imaging modes can be used to present received acoustic signals scattered or reflected by structures on or within the test sample. A coupling medium can be used to facilitate internal or external coupling of acoustic energy at the interface between the test probe assembly and the test sample. Summary of the Invention

[0004] Acoustic testing, such as ultrasound-based inspection, can involve focusing or beamforming techniques to aid in constructing a data plot or image representing a region of interest within a test sample. The use of an array of ultrasonic transducer elements can involve the use of a phased array beamforming approach and can be referred to as phased array ultrasonic testing (PAUT). For example, a delay-and-sum beamforming technique can be used, which involves coherently summing time-domain representations of received acoustic signals from each transducer element or aperture. Another approach can use a total focusing method (TFM) technique, in which one or more elements (or apertures defined by such elements) in the array are used to transmit acoustic pulses, while other elements are used to receive scattered or reflected acoustic energy, and a matrix of time-series (e.g., A-scan) representations is constructed corresponding to a sequence of transmit-receive cycles in which transmissions occur from different elements (or corresponding apertures) in the array. Generally, imaging is performed while the probe or structure under test is moved relative to one another. As mentioned above, a coupling medium, such as water, can be used at the interface between the test probe assembly and the test sample to efficiently couple acoustic energy to or from the test sample.

[0005] The inventors have recognized, among other things, that commonly available fluid coupling approaches can present various challenges. To address such challenges, an acoustic inspection device, such as that shown and described herein, can be used that provides a multi-layer structure for coupling energy from an acoustic transducer to a test sample. The multi-layer structure can include an internal fluid chamber, a first material, and a second material. A closed region can be formed between the second material layer and the test sample, such as by using a gasket or sealing arrangement. A couplant (e.g., water) can be provided at an interface between the test probe assembly and the test sample, such as an interface that includes both supply and suction ports. In this manner, couplant loss can be reduced or minimized. For example, the device can include a chassis for supporting an acoustic transducer, the chassis including a couplant fluid chamber, the couplant fluid chamber for pressurization relative to an external ambient environment of the chassis, the chamber arranged for acoustic excitation by the acoustic transducer. An applicator can be included for applying couplant fluid at the interface, such as by applying a flexible material layer that can be positioned in contact with the test sample. The couplant fluid chamber can include or define an aperture that couples the flexible material layer to the couplant fluid chamber and isolates the couplant fluid chamber from the external ambient environment, and the flexible material layer can conform to match the test sample at the interface, e.g., form a sealing region to retain couplant fluid applied via an applicator at the interface.

[0006] In one embodiment, the flexible material layer can flexibly protrude beyond the plane of the aperture to conform to the test sample, such as in response to application of fluid pressure within the fluid chamber. The device can include at least one pressurized port fluidly coupled to the couplant fluid chamber, the port defining a fluid inlet for fluid communication with a fluid pressure source. Here, the device can include a fluid circuit including a fluid inlet and a fluid outlet, the fluid circuit for flowing a first liquid stream through the couplant fluid chamber at a first pressure. In one embodiment, the device can include a port fluidly coupled to an applicator, the port providing flow of the couplant fluid to a porous medium fluidly connected to the applicator to maintain the couplant fluid at an interface.

[0007] The port fluidly coupled to the applicator can also be fluidly coupled to the couplant fluid chamber, such as coupled to a fluid outlet, to provide the first liquid stream to the porous medium after it exits the fluid chamber. The port fluidly coupled to the applicator can provide a flow of fluid couplant to a flow-restricting medium fluidly connected to the applicator to assist in wetting the interface. In one embodiment, the device can include a second layer of material, such as Aqualene™ or an elastomer, positioned between the flexible material layer and the fluid chamber. The chassis can also include or use a first portion sized and shaped to be removably coupleable to a second portion including the fluid chamber, such as to hold the flexible material layer along the edge of the fluid chamber to fluidly seal the fluid chamber. For example, the first portion can be removably coupleable to the second portion via at least one of a screw, a thumbscrew, a clamp, a latch, an adhesive, an insert and receptacle, or an interlocking relationship.

[0008] The chassis can also include or use a lubrication port positioned adjacent to the flexible material layer or fluid chamber, the lubrication port fluidly connected to the couplant fluid chamber. For example, the lubrication port can be positioned adjacent to the flexible material layer or fluid chamber, such as to provide couplant flow to a porous material positioned between the first portion and the test sample.

[0009] Each of the non-limiting embodiments described herein can stand alone or can be combined in various permutations or combinations with one or more of the other embodiments.

[0010] This Summary is intended to provide an overview of the subject matter of this patent application. It is not intended to provide an exclusive or exhaustive description of the invention. The Detailed Description is included to provide further information. [Brief explanation of the drawings]

[0011] In the drawings, which are not necessarily drawn to scale, like numerals may describe like components in different drawings. Like numerals with different letter suffixes may represent different instances of like components. The drawings illustrate generally, by way of example, various embodiments discussed in the present document, although not by way of limitation.

[0012] [Figure 1A] 1 illustrates a perspective view of one embodiment of a test probe assembly. [Figure 1B] 1 depicts a partial cross-sectional view of one embodiment of a test probe assembly. [Figure 1C] 1 depicts a partially exploded view of one embodiment of a test probe assembly. [Figure 2] 1 depicts the inspection device used for NDT of the test specimens. [Figure 3A] 1 depicts a perspective view of one embodiment of a probe assembly. [Figure 3B] 1 depicts an exploded view of one embodiment of a probe assembly. [Figure 3C] 10 depicts a partial cross-sectional view showing irrigation within one embodiment of a probe assembly. [Figure 3D] 10 depicts another partial cross-sectional view showing irrigation within one embodiment of a probe assembly. [Figure 4A] 10 depicts another embodiment of an assembled probe assembly. [Figure 4B] 1 depicts one embodiment of an unassembled probe assembly. [Figure 5] 1 illustrates one embodiment of an acoustic inspection system. [Figure 6] 1 is a flow chart illustrating a method for inspecting a test sample. [Figure 7] 7 is a flowchart further illustrating a method for inspecting the test sample from FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0013] Non-destructive testing (NDT) or non-destructive inspection (NDI) can be used to inspect the quality or other characteristics of a structure. NDT analysis can be performed on an object during or after manufacturing to ensure reliability, such as by monitoring for defects. For example, NDT can be used to identify voids, cracks, foreign objects, separations, delaminations, porosity, or other imperfections in manufactured components. Data acquired using NDT can be processed and used to determine the presence of anomalies in a structure.

[0014] Such probes, which may use ultrasonic, eddy current, or other NDT techniques, can be oriented to provide coverage areas of specific spaces or volumes, and multiple probes can be used to simultaneously inspect different areas of the object under test, such as to increase throughput. For example, analysis can be performed using a coupling medium (e.g., water) between the transducer and the surface of the object under test. In one approach, the test sample can be immersed in the coupling medium during NDT. Such an approach presents challenges, such as space and handling of large test samples, potential mechanical wear (e.g., corrosion), and relatively high couplant consumption. In another approach, rather than being immersed, the test sample can instead be coated, wetted, or sprayed with the coupling medium as the test probe assembly is moved relative to the test sample. Here, the test probe assembly can include a multilayer structure at or near the interface between the acoustic test probe assembly and the test sample. For example, a gasket or seal arrangement can be used to establish a couplant-filled region between the membrane formed by the multilayer structure and the test sample. Excess couplant can be collected around the periphery of the closed couplant-filled area, such as by using ports or other features to which suction can be applied to collect the couplant, for example, to reduce or minimize couplant loss while providing immersion at the interface between the probed objects.

[0015] Generally, NDT probes can be mounted on a fixture attached to a manipulator, such as a robotic arm, gantry, or multi-axis scanner, or can be manually operated. Because multiple different fixtures may be needed to accommodate different angles, sizes, thicknesses, and other dimensions of the structure under test, a variety of fixture configurations may exist. Inspecting structures with uneven (e.g., curved) profiles can also present challenges. For example, such profiles may require adjustments to the probe's position and proximity as different regions of the structure are inspected. Several passes along the length of the structure may be necessary to achieve the desired inspection coverage. It can also be difficult to establish a couplant fill area within the test probe assembly to mitigate the need to immerse the test sample during NDT. For example, the couplant may leak or run off the test sample if the sealing area is insufficient, or the test sample may require additional (e.g., manual) lubrication during testing, complicating the process. The inventors have recognized that, among other things, an adaptable fixture can be used to support NDT testing while accommodating various configurations to reduce the need to immerse the test specimen during testing.

[0016] 1A, 1B, and 1C depict one embodiment of a test probe assembly 100. The test probe assembly 100 can include a chassis 110 for supporting an acoustic transducer 102 and an applicator portion 120, which can apply a couplant to or near an interface 106 where the flexible material layer 104 can be positioned to contact a test sample. As depicted in the partial cross-sectional view shown in FIG. 1B, the test probe assembly 100 can also include or use a couplant fluid chamber 112, which can be pressurized relative to the external ambient environment of the chassis 110. The couplant fluid held within the chamber 112 can enable acoustic excitation by the acoustic transducer 102 and can also aid in visualizing or monitoring the test sample at the interface 106.

[0017] As shown in the partially exploded view of FIG. 1C , the chamber 112 may be composed of multiple sections separated by one or more gaskets or spacers 108. For example, the chamber 112 may define an aperture 124 that couples the flexible material layer 104 to the couplant fluid chamber 112 and isolates the couplant fluid chamber 112 from the external ambient environment. The flexible material layer 104 may be formed of a material that conforms to the test sample at the interface 106 based on the couplant fluid pressure within the fluid chamber 112. For example, the flexible material layer may be formed of a material including at least one of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), or perfluoroalkoxyalkane (PFA), or a combination thereof. The flexible material layer 104 may also be formed of a material selected to resist chemical contamination by the couplant fluid used in the test sample, such as hydrofluoroalkoxyalkane (HFA). Generally, flexible material layer 104 can be selected to have a stiffness compatible with or appropriate for sample testing, such as to facilitate or enhance visualization of sample structures at interface 106. In some embodiments, the material used for flexible material layer 104 can have a Young's modulus ranging from about 0.01 to about 1000 MPa. For example, in some embodiments, the Young's modulus can be from about 1 MPa to about 200 MPa. In some embodiments, the Young's modulus can be about 15 MPa or less, and in some embodiments, the Young's modulus can be about 10 MPa or less. In one embodiment, a sealing region including at least one sealing member, such as a spacer or gasket 108a, can be formed in or near flexible material layer 104. The sealing region can help retain couplant fluid applied via applicator portion 120 at interface 106. During operation and use, fluid pressure within the couplant fluid chamber 112 can cause the flexible material layer to flexibly protrude beyond the plane of the aperture 124 to conform to the test sample at the interface 106 .

[0018] The couplant fluids described herein are not limited to having acoustic couplant properties; rather, the couplant can have any acoustic properties, including non-transducer acoustic properties. While the couplant fluid is referred to herein as having acoustic properties, it is understood that the fluid can have any acoustic properties, such as, but not limited to, acoustic reflection, acoustic absorption, acoustic impedance, thermal conductivity, thermal diffusivity, mechanical stiffness, mechanical attenuation, and combinations thereof. While the couplant fluid is referred to herein as having acoustic properties, it is understood that the fluid can have any acoustic properties, such as, but not limited to, acoustic reflection, acoustic absorption, acoustic impedance, thermal conductivity, thermal diffusivity, mechanical stiffness, mechanical attenuation, and combinations thereof. Accordingly, the inspection methods described herein can include using any of the acoustic inspection techniques described above, such as, for example, inspection using an array of transducers or a single transducer.

[0019] 1B , the test probe assembly 100 can also include one or more ports 116 fluidly coupled to the applicator portion 120, which provide a flow of fluid couplant to a flow-restricting medium 126 fluidly connected to the applicator portion 120 to wet the test sample at the interface 106. In one embodiment, the ports 116 can be fluidly coupled to the couplant fluid chamber 112. Alternatively or additionally, the ports 116 can be fluidly coupled to a dedicated or separate chamber for providing external coupling fluid to the chamber 112 and in the flow-restricting medium 126. The flow-restricting medium 126 can act as a “water-soaked” sponge to retain the couplant therein while leaving couplant residue behind when the probe assembly 100 is translated relative to the test sample. For example, the flow-restricting medium 126 can be formed of or otherwise include a porous or water-absorbent material. The flow restricting medium 126 can include at least one of polyurethane foam, woven mesh or knit fabric, microporous film, thermoplastic polyurethane (TPU), polyethylene, polyester, polypropylene, polytetrafluoroethylene, polyacrylonitrile, polyvinyl alcohol, cellulose, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), or a combination thereof. In one embodiment, the test probe assembly 100 can also include a second material layer positioned between the flexible material layer 104 and the fluid chamber 112. In one embodiment, the second material can include an elastomer, such as a silicone elastomer, a thermoplastic elastomer, a styrene elastomer, or a combination thereof. For example, the second material layer can be formed at least in part from Aqualene™.

[0020] FIG. 2 illustrates an inspection apparatus used for NDT of a test sample. In one embodiment, the test probe assembly 100 includes or can use a mechanical linkage that can be used to attach the test probe assembly 100 to a manipulator 150, such as a robotic arm, gantry, multi-axis scanner, or other device, to facilitate semi-automated or automated inspection. The manipulator 150 can include a motion control system, such as a robotic controller, a positioning controller, or a motion planning algorithm. As depicted in FIG. 2, the manipulator 150 can include a robot, such as a robotic arm, configured to translate, rotate, twist, or otherwise manipulate the probe assembly 100. For example, the manipulator 150 can position the probe assembly 100 near an inspection site on a test sample 160. As described above with respect to FIG. 1, the arrangement of components within the test probe assembly 100 can provide a visualization area that is approximately the same size as the surface area of ​​the surface of the probe assembly 100 that contacts the test sample 160 at the interface. In this manner, when positioned via the manipulator 150, the test probe assembly 100 can inspect an entire test sample in a single test run. In one embodiment, the manipulator 150 can cause the probe assembly 100 to move in a serpentine pattern across the surface of the test sample 160 to inspect an entire area of ​​the test sample 160. For example, the manipulator 150 can translate and / or rotate the probe assembly 100 in two dimensions relative to the test sample 160 to inspect all areas of the test sample 160 during a single test run. As another example, the manipulator 150 can move the probe assembly 100 up and down relative to the test sample 160 to inspect all areas of the test sample 160 during a single test run. In one embodiment, if the test sample 160 includes an irregular or concave surface, the test probe assembly 100 can be rotated by the manipulator 150 to view areas around the test sample 160 while maintaining the position of the inspection area relative to the surface of the test sample 160.One or more linear variable differential transformers (LVDTs) can be used to provide feedback to assist in dynamic control of the movement of the manipulator 150 in response to changes in the contour, curvature, or shape of the test object. Other sensing devices for positioning the manipulator 150 can be used, such as electromechanical or opto-mechanical sensors.

[0021] 3A, 3B, 3C, and 3D depict another embodiment of a probe assembly. The probe assembly 300 may be similar to the probe assembly 100 described above. Accordingly, the probe assembly 300 may include or use similar components and may be used in a similar manner as those described above with respect to FIGS. 1A-1C. In one embodiment, the probe assembly 300 may include or use at least one acoustic transducer 302 disposed within a chassis 310 and an applicator 320 for applying couplant fluid to an interface where a flexible material layer 304 may be positioned to contact a test sample. The probe assembly 300 may also include a couplant fluid chamber 312 for pressurizing relative to an external ambient environment of the chassis 310. The fluid chamber 312 may define an aperture 324 exposing the flexible material layer 304, which isolates the couplant fluid chamber 312 from the external ambient environment, and the flexible material layer conforms to match the test sample at the interface. Additionally, test probe assembly 300 may also include a second layer of material 305 positioned between flexible layer of material 304 and fluid chamber 312. In one embodiment, second layer of material 305 may include an elastomer, such as, for example, Aqualene™.

[0022] 3A and 3B, the chassis 310 can include or use a first chassis portion 362 pivotally connected to a second chassis portion 364 via a pivot point 366. In one embodiment, the first chassis portion 362 and the second chassis portion 364 can include or use a pin and hole structure to connect them to one another, which can allow for axial and rotational movement of the chassis 310. In one embodiment, various components can be coupled to the second chassis portion 364, including the fluid chamber 312.

[0023] As depicted in the partial cross-sectional view of FIG. 3C , the test probe assembly 100 can also include one or more pressure ports 330 fluidly coupled to the couplant fluid chamber 112, the pressure ports 330 defining fluid inlets for fluid communication with a fluid pressure source. In one embodiment, the test probe assembly 100 can also include one or more fluid outlets 331. Couplant fluid can flow from the pressure ports 330 to the one or more fluid outlets 331 at a specified pressure. For example, the couplant chamber 112 can have fluid applied at a pressure ranging from about 0.5 bar to about 5 bar, such as from about 0.5 bar to about 4.0 bar, or from about 0.01 bar to about 10 bar in some embodiments. The viscosity of the couplant can be selected so that the material layer 104 flexibly protrudes to conform to the test sample at the interface 106 when the fluid is applied via the applicator portion 120. Alternatively, the fluid pressure within the couplant fluid chamber 112 can be selected so that the layer of material 104 remains relatively stationary as the fluid is applied via the applicator portion 120 .

[0024] 3D , the test probe assembly 300 can also include one or more lubrication ports 316 fluidly coupled to the applicator 320 to provide for the flow of fluid couplant to help maintain the couplant fluid at the interface between the probe assembly 300 and the test sample. For example, the one or more lubrication ports 316 can also be fluidly coupled to the couplant fluid chamber 112, e.g., via a fluid connection between a respective one of the one or more fluid outlets 331 and a respective one of the one or more lubrication ports. The test probe assembly can also include or use a pressure regulator to adjust the pressure of the couplant fluid chamber relative to the external ambient environment.

[0025] In one embodiment, the fluid circuit providing couplant fluid to one or more lubrication ports 316 or one or more pressurized ports 330 can be an open circuit fluidly connected to an open, non-pressurized reservoir holding the couplant fluid. Here, the couplant fluid can be pumped or drawn through tubing, such as by an electric pump, and then dispensed or recirculated into the reservoir. This technique can allow for better absorption of transient pressure fluctuations that occur when the test probe assembly is placed on the surface of the test sample. This technique also allows for a wider selection of couplant fluids, since the couplant fluid can be stored in a conventional, ready-to-use liquid form in a conventional container.

[0026] 4A and 4B depict another embodiment of a probe assembly. The probe assembly 400 may be similar to the probe assembly 100 and probe assembly 300 described above. Accordingly, the probe assembly 400 may include or use similar components and may be used in a similar manner as those described above with respect to FIGS. 1A-1C and 3A-3D. The chassis 410 of the probe assembly 400 may include a first portion 470 sized and shaped to be removably coupleable to a second portion 472. In one embodiment, the first portion 470 may be removably coupleable to the second portion 472 via at least one of a screw, a thumbscrew, a clamp, a latch, an adhesive, an insert and receptacle, and an interlocking relationship. As depicted in FIG. 4B, the second portion 472 may include at least one clamp screw 474 including a cam feature to clamp the first portion 470 and the second portion 472 in a coupled relationship. Additionally, when coupled to the second portion 472, the first portion 470 can retain a flexible material layer along the edge of the fluid chamber 412 to fluidly seal the fluid chamber 412. As used herein, the phrases “removably coupleable,” “removably couple,” “removable,” “coupleable,” and “couple” can refer to components that are mechanically connected to allow for insertion and removal. Such a configuration can allow for quick and easy integration or removal of components. Additionally, a flow-restricting medium 426 (similar to the flow-restricting medium 126 described above) can be included in the second removable portion 472. In one embodiment, the flow-restricting medium 426 can be removably coupleable to the second portion 472 via a mating feature, such as an adhesive or a receptacle.

[0027] FIG. 5 generally illustrates one embodiment comprising an acoustic inspection system 500 that can be used to implement at least a portion of one or more of the techniques shown and described herein. The inspection system 500 can include a test instrument 540, such as a handheld or portable assembly. The test instrument 540 can be electrically coupled to a probe assembly, such as using a multi-conductor interconnect 530. The probe assembly 550 can include one or more electroacoustic transducers, such as a transducer array 552 including respective transducers 154A-154N. The transducer array can follow a linear or curved contour, or can include an array of elements extending in two axes, such as providing a matrix of transducer elements. The elements need not have a square footprint or be arranged along a linear axis. The size and pitch of the elements can vary depending on the inspection application.

[0028] A modular probe assembly 550 configuration can be used that allows the test instrument 540 to be used with a variety of different probe assemblies 550. Generally, the transducer array 552 includes, for example, a piezoelectric transducer that can be acoustically coupled to a target 558 (e.g., a test sample or "object under test") via a coupling medium 556. The coupling medium can include a fluid or gel, or a solid membrane (e.g., an elastomer or other polymeric material), or a combination of fluid, gel, or solid structures. For example, the acoustic transducer assembly can include a transducer array coupled to a wedge structure including a rigid thermosetting polymer with known acoustic propagation properties (e.g., Rexolite® available from C-Lec Plastics Inc.), and water can be injected between the wedge and the structure under test as the coupling medium 556 during testing, or testing can be performed by otherwise immersing the interface between the probe assembly 550 and the target 558 in the coupling medium. The devices and techniques described herein can be used to enhance the coverage of the coupling medium 556 at the interface between the probe assembly 550 and the target 558 .

[0029] The test instrument 540 may include digital and analog electrical circuitry, such as a front-end circuit 522 including one or more transmit signal chains, receive signal chains, or switching circuitry (e.g., transmit / receive switching circuitry). The transmit signal chain may include amplifier and filter electrical circuitry to provide transmit pulses for delivery to the probe assembly 550 via the interconnect 530 for sonication of the target 558, and to receive scattered or reflected acoustic energy elicited in response to the sonication, thereby imaging or otherwise detecting defects 560 on or within the target 558 structure.

[0030] 5 shows a single probe assembly 550 and a single transducer array 552, other configurations can be used, such as multiple probe assemblies connected to a single test fixture 540, or multiple transducer arrays 552 used with single or multiple probe assemblies 550 for pitch / catch inspection modes. Similarly, test protocols can be performed using coordination among multiple test fixtures 540, for example, in response to an overall test scheme established from a master test fixture 540, or by another remote system such as computing equipment 508, or by a general-purpose computing device such as a laptop 532, tablet, smartphone, or desktop computer. The test scheme can be established in accordance with published standards or regulatory requirements and can be repeated, as illustrative examples, at initial production or for ongoing monitoring.

[0031] The receive signal chain of the front-end circuitry 522 may include one or more filter or amplifier circuits along with analog-to-digital conversion facilities to digitize echo signals received using the probe assembly 550. The digitization may be performed coherently to provide multiple channels of digitized data that are aligned or referenced to each other in time or phase. The front-end circuitry may be coupled to and controlled by one or more processor circuits, such as processor circuit 502 included as part of the test instrument 540. The processor circuit may be coupled to a memory circuit to execute instructions that cause the test instrument 540 to perform one or more of the following: transmit sound, acquire sound, process or store data related to the acoustic test, or otherwise perform techniques as shown and described herein. The test instrument 540 may be communicatively coupled to other portions of the system 500, such as using a wired or wireless communication interface 520.

[0032] For example, performance of one or more techniques as shown and described herein can be achieved on the test instrument 540 or using other processing or storage facilities, such as using the computing facilities 508, or general-purpose computing devices such as laptops 532, tablets, smartphones, desktop computers, etc. For example, processing tasks that would be unnecessarily slow if performed on the test instrument 540 or if performed beyond the capabilities of the test instrument 540 may be performed remotely (e.g., on a separate system), e.g., in response to a request from the test instrument 540. Similarly, storage of intermediate data, such as, e.g., A-scan matrices of imaging data or time series data, or other representations of such data, may be achieved using remote facilities communicatively coupled to the test instrument 540. The test instrument may include a display 510, such as for presenting configuration information or results, and input devices 512, including one or more of a keyboard, trackball, function keys or softkeys, a mouse interface, a touch screen, a stylus, etc., for receiving operator commands, configuration information, or responses to queries.

[0033] FIG. 6 is a flow chart illustrating a method for inspecting a test sample.

[0034] In one embodiment, at 610, the method can include placing the test sample in contact with the couplant fluid.

[0035] At 620, the method can include placing the test sample in contact with a test head coupled to the test head, the test head including at least one acoustic transducer.

[0036] At 630, the method can include varying the pressure and flow of couplant fluid relative to the aperture to adapt the shape of the flexible material layer to conform to the test sample at an interface where the flexible material layer can be positioned to contact the test sample. For example, varying can include pressurizing the couplant fluid chamber such that the flexible material layer flexibly protrudes beyond the plane of the aperture in response to fluid pressure being applied within the fluid chamber to conform to the test sample.

[0037] At 640, the method can include transmitting one or more acoustic pulses. The method can also include receiving acoustic echoes. For example, acoustic signals can be transmitted or received, such as using couplant fluid in a couplant fluid chamber.

[0038] At 650, the method may include presenting data indicative of a characteristic of the test specimen based on characteristics of the received acoustic echoes. For example, presenting the data may include presenting one or more total focusing method (TFM) images or one or more full matrix acquisition (FMC) A-scans (amplitude time series). The data may be interpreted by a user, such as to identify defects or other characteristics of the test specimen.

[0039] The couplant fluid may also be used to flow through a couplant fluid chamber of the test head, which may include or define an aperture that exposes a flexible material layer that isolates the couplant fluid chamber from the external ambient environment.

[0040] The method can also include providing a flow of fluid couplant to the flow-restricting medium to wet the interface. In one embodiment, the method can include maintaining the couplant fluid at the interface within a sealed region defined by the at least one seal member. In one embodiment, the method can include establishing or adjusting a pressure and flow of couplant fluid delivered to the interface by an applicator to apply couplant residue to the test sample while reducing eruptions from the couplant interface.

[0041] Figure 7 is a flow chart further illustrating a method for inspecting the test sample from Figure 6. In one embodiment, at 710, the method can include adjusting the fluid pressure of at least one pressurized port fluidly coupled to the couplant fluid chamber.

[0042] In one embodiment, at 720, the method can include circulating couplant fluid through the fluid circuitry of the test head.

[0043] At 730, circulating can include flowing the first liquid stream through a couplant fluid chamber.

[0044] At 740, in one embodiment, the method can include providing a flow of fluid couplant to the porous medium to maintain the couplant fluid at the interface.

[0045] Notes and Examples Aspect 1 is an acoustic inspection device comprising: a chassis configured to support an acoustic transducer, the chassis having a couplant fluid chamber configured to be pressurized relative to an external ambient environment of the chassis, the chamber arranged to be acoustically excited by the acoustic transducer; and an applicator configured to apply couplant fluid at an interface where a flexible material layer is arranged to contact a test sample, the couplant fluid chamber having or defining an aperture, the aperture coupling the flexible material layer to the couplant fluid chamber and isolating the couplant fluid chamber from the external ambient environment, the flexible material layer configured to conform to a shape to match the test sample at the interface.

[0046] In aspect 2, the subject matter described in aspect 1, wherein a sealing area is formed, the sealing area is defined by at least one seal member, and the sealing area is configured to maintain couplant fluid applied via the applicator at the interface.

[0047] In aspect 3, the subject matter of aspect 1 or 2 further comprises a flexible material layer, the flexible material layer flexibly protruding beyond the plane of the aperture in response to fluid pressure being applied within the fluid chamber to conform to the test sample.

[0048] In Example 4, the subject matter of any one of Examples 1-3 includes a flexible material layer, the flexible material layer comprising at least one of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), or perfluoroalkoxyalkane (PFA), or a combination thereof.

[0049] In aspect 5, the subject matter described in any one of aspects 1 to 4 includes at least one pressure port fluidly coupled to the couplant fluid chamber, the pressure port defining a fluid inlet for fluid communication with a fluid pressure source.

[0050] In aspect 6, the subject matter described in aspect 5 includes a fluid circuit including a fluid inlet and a fluid outlet, the fluid circuit configured to flow a first liquid stream through the couplant fluid chamber at a first pressure.

[0051] In embodiment 7, the subject matter described in embodiment 6 includes a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a porous medium fluidly connected to the applicator to maintain the couplant fluid at the interface.

[0052] In embodiment 8, the subject matter of embodiment 7, wherein the port fluidly coupled with the applicator is also fluidly coupled with the couplant fluid chamber.

[0053] In embodiment 9, the subject matter of embodiment 7 or 8, wherein the port fluidly coupled to the applicator is also fluidly coupled to the fluid outlet and is configured to provide the first liquid stream to the porous medium after the first liquid stream exits the fluid chamber.

[0054] In aspect 10, the subject matter described in any one of aspects 1 to 9 includes a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a flow-restricting medium fluidly connected to the applicator to wet the interface, and the port being fluidly coupled to the couplant fluid chamber.

[0055] In embodiment 11, the subject matter of embodiment 10, wherein the flow-restricting medium comprises a porous material.

[0056] In example 12, the subject matter of example 11, wherein the porous material comprises a water-absorbing material comprising at least one of polyurethane foam, woven mesh or knitted fabric, microporous film, thermoplastic polyurethane (TPU), polyethylene, polyester, polypropylene, polytetrafluoroethylene, polyacrylonitrile, polyvinyl alcohol, cellulose, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), or a combination thereof.

[0057] In embodiment 13, the subject matter of any one of embodiments 1-12, comprising a second layer of material positioned between the flexible layer of material and the fluid chamber.

[0058] In example 14, the subject matter of example 13, wherein the second material comprises an elastomer including at least one of a silicone elastomer, a thermoplastic elastomer, a styrene elastomer, or a combination thereof.

[0059] In embodiment 15, the subject matter of embodiment 14, wherein the second material comprises Aqualene™.

[0060] In aspect 16, the subject matter described in any one of aspects 1 to 15 further comprises an acoustic transducer element positioned adjacent to the fluid chamber, the acoustic transducer element configured to at least one of transmit or receive acoustic signals using couplant fluid in the couplant fluid chamber.

[0061] In aspect 17, the subject matter described in any one of aspects 1 to 16, wherein the chassis includes a first portion sized and shaped to be removably coupled to a second portion including a fluid chamber, and the first portion is configured to hold a flexible material layer along an edge of the fluid chamber to fluidly seal the fluid chamber when coupled to the second portion.

[0062] In aspect 18, the subject matter described in aspect 17, wherein the first part is removably connectable to the second part via at least one of screws, thumbscrews, clamps, latches, adhesive, inserts and receptacles, and interlocking relationships.

[0063] In aspect 19, the subject matter of aspect 17 or 18, wherein the chassis includes a lubrication port positioned adjacent to the flexible material layer or the fluid chamber, the lubrication port being fluidly connected to the couplant fluid chamber.

[0064] In aspect 20, the subject matter described in any one of aspects 17 to 19, wherein the chassis includes a lubrication port positioned adjacent to the flexible material layer or fluid chamber, the lubrication port configured to provide couplant flow to a porous material positioned between the first portion and the test sample.

[0065] Aspect 21 is a system for acoustic testing, the system comprising: a test head including at least one acoustic transducer disposed within a chassis, the chassis having a couplant fluid chamber configured to be pressurized relative to an external ambient environment of the chassis, the chamber being arranged to be acoustically excited by the acoustic transducer; and an applicator configured to apply couplant fluid at an interface where a flexible material layer is arranged to contact the test sample, the couplant fluid chamber having or defining an aperture that exposes the flexible material layer that isolates the couplant fluid chamber from the external ambient environment, the flexible material layer being configured to conform to the shape of the test sample at the interface.

[0066] In aspect 22, the subject matter described in aspect 21, wherein a sealing area is formed, the sealing area is defined by at least one seal member, and the sealing area is configured to maintain couplant fluid applied via the applicator at the interface.

[0067] In aspect 23, the subject matter of aspect 21 or 22 includes an inspection head manipulator configured to controllably position the inspection head relative to the test sample.

[0068] In embodiment 24, the subject matter of any one of embodiments 21-23, wherein the inspection head includes an integral conveyor mechanism configured to controllably transport the test sample through the chamber for acoustic inspection.

[0069] In embodiment 25, the subject matter of any one of embodiments 21-24, further comprising a pressure regulator for regulating the pressure of the couplant fluid chamber relative to the external ambient environment.

[0070] In embodiment 26, the subject matter described in any one of embodiments 21 to 25, further comprising a flexible material layer, the flexible material layer flexibly protruding beyond the plane of the aperture in response to fluid pressure being applied within the fluid chamber to conform to the test sample.

[0071] In aspect 27, the subject matter described in any one of aspects 21 to 26 includes at least one ultrasonic transducer configured to excite couplant fluid in the couplant fluid chamber.

[0072] In aspect 28, the subject matter described in aspect 27 includes at least one optical transducer configured to measure acoustic excitation and / or ejection of couplant fluid within the couplant fluid chamber.

[0073] In embodiment 29, the subject matter of any one of embodiments 21 to 28 includes a flexible material layer, the flexible material layer comprising at least one of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), or perfluoroalkoxyalkane (PFA), or a combination thereof.

[0074] In embodiment 30, the subject matter described in any one of embodiments 21 to 29 includes at least one pressure port fluidly coupled to the couplant fluid chamber, the pressure port defining a fluid inlet for fluid communication with a fluid pressure source.

[0075] In aspect 31, the subject matter described in aspect 30 includes a fluid circuit including a fluid inlet and a fluid outlet, the fluid circuit configured to flow a first liquid stream through the couplant fluid chamber at a first pressure.

[0076] In aspect 32, the subject matter described in aspect 31 includes a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a porous medium fluidly connected to the applicator so as to maintain the couplant fluid at the interface.

[0077] In embodiment 33, the subject matter described in embodiment 32, wherein the port fluidly coupled with the applicator is also fluidly coupled with the couplant fluid chamber.

[0078] In aspect 34, the subject matter of aspect 32 or 33, wherein the port fluidly coupled to the applicator is also fluidly coupled to the fluid outlet and is configured to provide the first liquid stream to the porous medium after the first liquid stream exits the fluid chamber.

[0079] In embodiment 35, the subject matter described in any one of embodiments 21 to 34 includes a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a flow-restricting medium fluidly connected to the applicator to wet the interface, and the port being fluidly coupled to the couplant fluid chamber.

[0080] In embodiment 36, the subject matter of embodiment 35, wherein the flow-restricting medium comprises a porous material.

[0081] In embodiment 37, the subject matter of embodiment 36, wherein the porous material comprises a water-absorbing material comprising at least one of polyurethane foam, woven mesh or knitted fabric, microporous film, thermoplastic polyurethane (TPU), polyethylene, polyester, polypropylene, polytetrafluoroethylene, polyacrylonitrile, polyvinyl alcohol, cellulose, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), or a combination thereof.

[0082] In embodiment 38, the subject matter of any one of embodiments 21-37, comprising a second layer of material positioned between the flexible layer of material and the fluid chamber.

[0083] In aspect 39, the subject matter of aspect 38, wherein the second material comprises an elastomer including at least one of a silicone elastomer, a thermoplastic elastomer, a styrene elastomer, or a combination thereof.

[0084] In embodiment 40, the subject matter of embodiment 39, wherein the second material comprises Aqualene™.

[0085] In aspect 41, the subject matter described in any one of aspects 21 to 40 further comprises an acoustic transducer element positioned adjacent to the fluid chamber, the acoustic transducer element configured to perform at least one of transmitting or receiving an acoustic signal using couplant fluid in the couplant fluid chamber.

[0086] In aspect 42, the subject matter described in any one of aspects 21 to 41, wherein the chassis includes a first portion sized and shaped to be removably connectable to a second portion including a fluid chamber, and the first portion is configured to hold a flexible material layer along an edge of the fluid chamber to fluidly seal the fluid chamber when connected to the second portion.

[0087] In aspect 43, the subject matter described in aspect 42, wherein the first part is removably connectable to the second part via at least one of screws, thumbscrews, clamps, latches, adhesive, inserts and receptacles, and interlocking relationships.

[0088] In aspect 44, the subject matter described in aspect 42 or 43, wherein the chassis includes a lubrication port positioned adjacent to the flexible material layer or the fluid chamber, the lubrication port being fluidly connected to the couplant fluid chamber.

[0089] In aspect 45, the subject matter described in any one of aspects 42 to 44, wherein the chassis includes a lubrication port positioned adjacent to the flexible material layer or fluid chamber, the lubrication port configured to provide couplant flow to a porous material positioned between the first portion and the test sample.

[0090] Aspect 46 is a method for inspecting a test sample, the method including: placing the test sample in contact with a couplant fluid; placing the test sample in contact with an inspection head coupled to an inspection head including at least one acoustic transducer, the inspection head configured to flow the couplant fluid through a couplant fluid chamber of the inspection head, the couplant fluid chamber including or defining an aperture, the aperture exposing a flexible material layer that isolates the couplant fluid chamber from an external ambient environment; varying the pressure and flow of the couplant fluid relative to the aperture to conform the shape of the flexible material layer to match the test sample at an interface where the flexible material layer is positioned to contact the test sample; transmitting one or more acoustic pulses via the acoustic transducer; receiving acoustic echoes corresponding to the one or more acoustic pulses; and presenting data indicative of a characteristic of the test sample based on characteristics of the received acoustic echoes.

[0091] In embodiment 47, the subject matter described in embodiment 46 includes maintaining a couplant fluid at an interface within a sealed region defined by the at least one seal member.

[0092] In aspect 48, the subject matter described in aspect 46 or 47 includes establishing or adjusting the pressure and flow of couplant fluid supplied to the interface by the applicator to apply couplant residue to the test sample while reducing couplant ejection from the interface.

[0093] In embodiment 49, the subject matter described in any of embodiments 46-48, wherein the varying includes pressurizing the couplant fluid chamber such that the flexible material layer flexibly protrudes beyond the plane of the aperture in response to fluid pressure being applied within the fluid chamber to conform to the test sample.

[0094] In embodiment 50, the subject matter described in any one of embodiments 46-49 includes adjusting fluid pressure of at least one pressure port fluidly coupled to the couplant fluid chamber.

[0095] In embodiment 51, the subject matter described in embodiment 50 includes circulating couplant fluid through a fluid circuit, including flowing a first liquid stream through the couplant fluid chamber at a first pressure.

[0096] In embodiment 52, the subject matter of embodiment 51 includes providing a flow of fluid couplant to the porous medium to maintain the couplant fluid at the interface.

[0097] In embodiment 53, the subject matter of any one of embodiments 46-52 includes providing a flow of fluid couplant to the flow-restricting medium to wet the interface.

[0098] In aspect 54, the subject matter described in any one of aspects 46 to 53 includes transmitting or receiving an acoustic signal using couplant fluid in a couplant fluid chamber.

[0099] Embodiment 55 is at least one machine-readable medium comprising instructions that, when executed by a processing circuit, cause the processing circuit to perform operations to implement any of embodiments 1-54.

[0100] A fifty-sixth embodiment is a device including the mounting means of any one of the first to fourth embodiments.

[0101] Aspect 57 is a system that implements any of aspects 1 to 54.

[0102] Aspect 58 is a method for implementing any of aspects 1 to 54.

[0103] Each of the non-limiting aspects described in this document can stand alone or can be combined in various permutations or combinations with one or more of the other aspects or other subject matter described herein.

[0104] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are also generally referred to as "examples." Such examples may include elements in addition to those shown or described. However, the inventors also contemplate examples in which only those elements shown or described are provided. Furthermore, the inventors also contemplate examples using any combination or permutation of those elements (or one or more aspects thereof) shown or described with respect to a particular example (or one or more aspects thereof) shown or described herein or with respect to other examples (or one or more aspects thereof).

[0105] In the event of a conflict of usage between this document and any document so incorporated by reference, the usage in this document shall take precedence.

[0106] As used herein, the terms "a" or "an" are used to include one or more, as is common in patent documents, regardless of any other instance or usage of "at least one" or "one or more." As used herein, the term "or" is used to refer to a non-exclusive or, unless otherwise indicated, such that "A or B" includes "A but not B," "B but not A," and "A and B." As used herein, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein." Also, in the claims, the terms "including" and "comprising" are open-ended, i.e., systems, devices, articles, compositions, formulations, or processes that include elements in addition to those listed after such terms in a claim are still considered to be within the scope of that claim. Moreover, in the claims, the terms "first," "second," and "third," etc., are used merely as labels and are not intended to impose numerical requirements on their objects.

[0107] Embodiments of the methods described herein may be at least partially machine or computer-implemented. Some examples may include computer-readable or machine-readable media encoded with instructions operable to configure an electronic device to perform the methods described in the above examples. Implementations of such methods may include code, such as microcode, assembly language code, higher-level language code, etc. Such code may include computer-readable instructions for performing various methods. The code may form part of a computer program product. Furthermore, in embodiments, the code may be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media may include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memory (RAM), read-only memory (ROM), etc.

[0108] The above description is intended to be illustrative, not limiting. For example, the examples described above (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be used, for example, by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment.

Claims

1. 1. An acoustic inspection apparatus, comprising: a chassis configured to support an acoustic transducer, the chassis including a couplant fluid chamber for pressurizing the chamber relative to an external ambient environment of the chassis, the chamber being arranged for acoustic excitation by the acoustic transducer; an applicator configured to apply couplant fluid at an interface where the flexible material layer is positioned in contact with the test specimen; at least one pressure port fluidly coupled with the couplant fluid chamber, the pressure port defining a fluid inlet for fluid communication with a fluid pressure source; a fluid circuit including the fluid inlet and fluid outlet, the fluid circuit configured to flow a first liquid stream through the couplant fluid chamber at a first pressure; a port fluidly coupled to the applicator, the port providing a flow of couplant fluid to a porous medium fluidly connected to the applicator to maintain the couplant fluid at the interface; Equipped with An acoustic inspection device wherein the couplant fluid chamber comprises or defines an aperture that couples a flexible material layer to the couplant fluid chamber and isolates the couplant fluid chamber from the external ambient environment.

2. 10. The device of claim 1, wherein a sealing area is formed, the sealing area being defined by at least one seal member, and the sealing area being configured to maintain couplant fluid applied via the applicator at the interface.

3. the flexible material layer; 3. The device of claim 1, wherein the flexible material layer flexibly protrudes beyond the plane of the aperture in response to fluid pressure being applied within the fluid chamber to conform to the test sample.

4. The device of claim 1 , wherein the port fluidly coupled to the applicator is also fluidly coupled to the couplant fluid chamber.

5. 5. The device of claim 4, wherein the port fluidly coupled to the applicator is also fluidly coupled to the fluid outlet and is configured to provide the first liquid stream to the porous medium after the first liquid stream exits the fluid chamber.

6. 2. The device of claim 1, further comprising a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a porous flow-restricting medium fluidly connected to the applicator to wet the interface, the port being fluidly coupled to the couplant fluid chamber.

7. The device of claim 1 , comprising a second layer of material positioned between the flexible layer of material and the fluid chamber.

8. 10. The device of claim 1, further comprising an acoustic transducer element positioned adjacent to the fluid chamber, the acoustic transducer element configured to at least one of transmit or receive acoustic signals using the couplant fluid in the couplant fluid chamber.

9. the chassis includes a first portion sized and shaped to be removably coupleable to a second portion including the fluid chamber; 2. The device of claim 1, wherein the first portion, when coupled to the second portion, is configured to hold the flexible material layer along an edge of the fluid chamber to fluidly seal the fluid chamber.

10. 10. The device of claim 9, wherein the chassis includes a lubrication port positioned adjacent the flexible material layer or the fluid chamber, the lubrication port being fluidly connected to the couplant fluid chamber.

11. 1. A system for acoustic inspection, the system comprising: an inspection head; The inspection head includes: at least one acoustic transducer disposed within a chassis, the chassis including a couplant fluid chamber configured to be pressurized relative to an ambient environment external to the chassis, the chamber configured for acoustic excitation by the acoustic transducer; an applicator configured to apply couplant fluid at an interface where the flexible material layer is positioned to contact the test sample; the couplant fluid chamber includes or defines an aperture exposing a flexible material layer isolating the couplant fluid chamber from the external ambient environment, the flexible material layer being configured to conform to the test sample at the interface; The system, wherein the inspection head comprises a port fluidly coupled to the applicator, the port providing a flow of fluid couplant to a porous medium fluidly connected to the applicator to maintain the couplant fluid at the interface.

12. A method of inspecting a test sample using the system of claim 11, said method comprising: placing the test sample in contact with a couplant fluid; placing the test specimen in contact with an inspection head including at least one acoustic transducer; varying the pressure and flow of couplant fluid relative to the aperture to cause the flexible layer of material to conform to the test specimen at an interface where the flexible layer of material is positioned to contact the test specimen; transmitting one or more acoustic pulses through the acoustic transducer; receiving acoustic echoes corresponding to the one or more acoustic pulses; and presenting data indicative of a characteristic of the test sample based on characteristics of the received acoustic echoes.

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