Acoustic Microtexture Region Detection Without Destructive Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inspection methods for microstructural characteristics in metal alloys, such as titanium and nickel alloys, often require destructive testing and extensive surface preparation, which can damage the components and are inefficient.
Innovation Solution
Non-destructive inspection systems and methods using acoustic or electromagnetic energy to assess microstructural characteristics, including microtexture regions, without the need for polished surfaces, allowing for the detection of grain size, orientation, and other material anomalies, utilizing sensors and subsystems, and subsystems, and subsystems, and independent transducer arrangements to analyze signal data for MTR characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing methods are used to inspect microstructural characteristics, then measurement precision is improved, but the specimen is damaged and inspection efficiency is reduced
Solution Approach 1:
The patent replaces mechanical destructive testing methods with acoustic emission detection. Acoustic sensors detect sound waves generated by acoustic stimulation of the specimen, allowing non-destructive measurement of microstructural characteristics such as grain size and phase composition without damaging the specimen.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary between the inspection system and the specimen. The acoustic waves interact with the microstructure to generate detectable signals that carry information about material properties, enabling indirect non-destructive measurement without direct mechanical contact or damage.
2Measurement precision
If extensive surface preparation is performed, then measurement precision is improved, but inspection time increases and productivity decreases
Solution Approach 1:
The patent enables the specimen to serve itself by using its own acoustic response to reveal microstructural characteristics. The acoustic emission technique requires no external surface preparation or complex sample handling, as the specimen's inherent acoustic properties provide the measurement signals directly.
Solution Approach 2:
The patent substitutes mechanical surface preparation procedures with acoustic field interaction. Instead of mechanically polishing or preparing surfaces to enhance detection, the system uses acoustic waves to penetrate and interact with the microstructure, eliminating the need for time-consuming surface preparation while maintaining measurement precision.
3Measurement precision
If traditional inspection methods are used, then detection capability is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent extracts the essential detection function from complex traditional inspection systems. By using acoustic emission, the system isolates the core measurement capability to simple acoustic sensors and signal processing, eliminating the need for complex mechanical preparation equipment, specialized sample holders, and multi-step inspection procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the identification of microstructural characteristics without damaging the specimen, facilitating efficient evaluation of peened and machined surfaces, and providing insights into material properties that impact performance, enabling informed decision-making on component disposition and manufacturing adjustments.
Implementation Method 1
The acoustic transducer transmits acoustic waves through a volume of the specimen and receives data indicative of the acoustic waves scattered or reflected from the specimen
Implementation Method 2
The electromagnetic transducer transmits electromagnetic waves through a volume of the specimen and receives data indicative of the electromagnetic waves scattered or reflected from the specimen
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Provided herein are inspection systems and methods for detecting MTR present within a subsurface volume of a specimen (102). The approaches use acoustic transducers (106) and, optionally, near-surface sensors (134) to introduce inspecting energy into the specimen (102). Signal data (120) representative of the inspecting energy is analyzed to detect MTRs. In some approaches, a shift in a frequency distribution of the signal data (130) is determined. In other approaches, a distribution of values for a given characteristic of the signal data (130), such as amplitude or frequency, is computed and a quantified description of the distribution is computed. Response scores and/or intensity maps can be generated for the specimen (102) based on the analysis of the signal data (130). MTR scores indicative of MTR in the specimen (102) can be correlated to the response score and/or intensity map (2724, 2728). The specimen (102) can then be dispositioned based on the response scores and/or intensity map (2724, 2728) and their correlation with the MTR scores.