Additive Manufactured Adaptor for Ultrasonic Probe Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ultrasonic inspection of additive manufactured objects with complex geometries is challenging due to features like cavities, voids, missing backwalls, inconsistent surface geometry, and lack of suitable probe coupling locations, which can lead to inaccurate results and require disassembly or expensive computer-aided tomographic inspection.
Innovation Solution
An adaptor formed via additive manufacturing, including a probe receiver and a coupling portion, is used to accurately position the ultrasonic probe with respect to the axes of force transmission within the object, allowing for precise ultrasonic inspection without disassembly and using the same material as the test object to minimize material-related errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ultrasonic inspection methods are used on additive manufactured objects with complex geometries, then inspection can be performed, but accurate results cannot be obtained due to cavities, voids, missing backwalls, and inconsistent surface geometry
Solution Approach 1:
The patent introduces an adaptor as an intermediary device between the ultrasonic probe and the additive manufactured object. The adaptor includes a coupling portion that interfaces with the object's surface and a probe receiver that positions the ultrasonic probe. This intermediary structure compensates for the complex geometry, cavities, and surface inconsistencies, enabling accurate ultrasonic inspection without direct probe contact with the problematic surfaces.
Solution Approach 2:
The inspection system is segmented into separate functional components: the adaptor (with coupling portion and probe receiver) and the ultrasonic probe. This segmentation allows the adaptor to be designed specifically for interfacing with the complex geometry of additive manufactured objects, while the probe remains a standard component. The adaptor can be removed and replaced without affecting the probe, facilitating easier system reconfiguration.
2Measurement precision
If disassembly is performed to inspect features like missing backwalls and cavities, then inspection access is improved, but structural integrity and inspection time are compromised
Solution Approach 1:
The adaptor serves as a mediator that enables inspection of internal features like missing backwalls and cavities through the object's existing surfaces. By positioning the ultrasonic probe through the adaptor on accessible surfaces, the system can detect internal defects without requiring disassembly, thereby maintaining structural integrity while reducing inspection time.
3Ease of manufacture
If different materials are used for the adaptor and test object, then adaptor manufacturing is simplified, but material-related errors and inspection accuracy deteriorate
Solution Approach 1:
The patent specifies that the adaptor should be formed from the same or similar material as the additive manufactured object being inspected. This homogeneity ensures that the adaptor has compatible acoustic properties with the object, minimizing material-related errors and maximizing inspection accuracy. The adaptor can still be manufactured using additive manufacturing processes, maintaining ease of manufacture while achieving material compatibility.
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
The adaptor enables more accurate and efficient ultrasonic testing of complex objects by providing a precise alignment interface, reducing inspection time and maintaining the structural integrity of the test object, while allowing for inspection of features like missing backwalls and cavities without disassembly.
Implementation Method 1
As the ultrasonic waves contact and penetrate the test object, they can reflect from features such as outer surfaces, internal structural components, and defects which can be present in the materials of the test object
Implementation Method 2
an adaptor formed via additive manufacturing, including a probe receiver and a coupling portion, is used to accurately position the ultrasonic probe with respect to the axes of force transmission within the object
Data Source
AI summary
A device for use in inspecting a test object is provided. The device can include a body including a first end and a second end. The second end can be opposite the first end. The device can also include a probe receiver located at the first end of the body. The probe receiver can be configured to receive an ultrasonic probe. The device can further include a coupling portion located at the second end of the body. The coupling portion can be configured to position the ultrasonic probe with respect to an axis of force transmission of a test object or normal to one or more material layers of the test object during an ultrasound inspection of the test object. Methods of forming the device and performing ultrasonic inspection of a test object with the device are also provided.