Bonded Structure Inspection With Phased-Array Ultrasonic Refraction

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Solution Overview

Problem

Current methods for inspecting bondlines in bonded structures, such as those in aircraft components, risk weakening or breaking the bondline, leading to potential scrapping of the structure.

Innovation Solution

A method and system using phased array ultrasonic transducers to project acoustic waves at a non-zero angle into bonded structures, determining the total refraction, and comparing it to predefined values to detect out-of-tolerance conditions, thereby avoiding damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If Laser Bond Inspection Detection is used to inspect bondlines, then measurement precision is improved, but the bondline strength is weakened or broken

Engineering Contradiction:

Improvebondline inspection accuracyVSAvoidbondline strength

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The patent replaces laser-based inspection methods with ultrasonic acoustic wave methods. Instead of using high-intensity laser beams that can thermally damage the bondline, the invention uses mechanical acoustic waves at lower intensities to probe the bondline properties through refraction measurements, thereby maintaining bondline strength while achieving inspection precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces acoustic waves as an intermediary medium to inspect the bondline indirectly. Rather than directly interacting with the bondline in a way that causes damage (as laser does), acoustic waves pass through the bonded structure and interact with the bondline properties through refraction, allowing measurement without direct damaging contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If Laser Bond Inspection Detection is used, then inspection capability is improved, but productivity is reduced due to potential scrapping

Engineering Contradiction:

Improvebondline detection capabilityVSAvoidinspection throughput

Core Design Contradiction:

Difficulty of detecting and measuringVSProductivity

Solution Approach 1:

The patent converts the potential harm of inspection into a benefit by using acoustic refraction measurements that do not damage the bondline. The refraction of acoustic waves at the bondline interface provides useful information about bond quality while preserving the bondline integrity, thus eliminating the need to scrap inspected parts and improving overall productivity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Measurement precision

If acoustic waves are projected at a non-zero angle, then measurement precision is improved through total refraction, but device complexity increases

Engineering Contradiction:

Improvetotal refraction measurement accuracyVSAvoidtransducer array configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the ultrasonic transducer into multiple elements arranged in a phased array. By segmenting the transducer, the system can electronically control the angle of acoustic wave projection and focus, enabling precise measurement of total refraction at the bondline interface without requiring complex mechanical positioning systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs dynamic phase control of the ultrasonic elements to adjust the projection angle of acoustic waves. By dynamically changing the phase relationships between elements, the system can steer the acoustic beam at different angles to optimize refraction measurements, providing measurement precision without fixed complex mechanical structures.

Inventive Principle:

Principle #15Dynamics

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

Ensures non-destructive inspection of bondlines by identifying out-of-tolerance conditions without causing structural weakness, allowing for effective quality control and reducing scrap rates.

Implementation Method 1

projecting acoustic waves into the bonded structure at a non-zero angle relative to a normal axis defined by an external surface of the first structural member... determining a magnitude of a total refraction of the acoustic waves

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS12447694B2Methods and systems for inspecting bonded structures

Publication Date: 2025.10.21 THE BOEING CO

AI summary

A method for inspecting a bonded structure, the bonded structure having a first structural member, a second structural member, and a bondline between the first structural member and the second structural member, includes projecting acoustic waves into the bonded structure at a non-zero angle relative to a normal axis defined by an external surface of the first structural member. The method further includes determining a magnitude of a total refraction of the acoustic waves after the acoustic waves pass through the bonded structure and comparing the magnitude of the total refraction to a predefined value.