Real-Time 3D Ultrasonic Imaging of Composite Laminate Defects
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Solution Overview
Problem
Existing non-destructive testing methods face challenges in efficiently visualizing defects within composite materials, particularly wrinkles, due to limitations in acoustic coupling and resolution, especially for large components like aircraft wings and fuselages, leading to impractical infrastructure requirements and reduced scanning resolution.
Innovation Solution
A system utilizing ultrasonic transducers with a processor and display, capable of emitting and receiving ultrasonic waves to generate B-scans and 3-D graphical representations, which calculates wrinkle aspects and depths, and provides real-time visualization of defects in composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional acoustic coupling methods are used for ultrasonic testing of large components, then the testing can be performed with conventional equipment, but the scanning resolution is reduced and infrastructure requirements become impractical
Solution Approach 1:
The patent replaces traditional mechanical acoustic coupling methods (requiring water columns, immersion tanks, or gel application) with a dry-coupled ultrasonic transducer system. The transducer directly contacts the composite material surface through a simple interface, eliminating the need for complex fluid handling infrastructure while maintaining ultrasonic wave transmission for high-resolution defect detection.
2Reliability
If traditional ultrasonic testing methods are used, then the equipment is simpler, but the ability to detect wrinkles and defects in composite materials is insufficient
Solution Approach 1:
The patent integrates multiple functions into a single portable system: the ultrasonic transducer performs both transmission and reception of ultrasonic waves, the processor executes multiple analysis algorithms (A-scan, B-scan, C-scan imaging, wrinkle detection), and the display provides real-time visualization. This multi-functional integration enhances defect detection reliability while keeping the system portable and relatively simple.
Solution Approach 2:
The patent introduces a processor as an intermediary between the ultrasonic transducer and the display system. The processor receives raw ultrasonic signals, processes them through various algorithms to extract defect information, and generates visual representations. This intermediary component enables sophisticated defect detection capabilities while maintaining a straightforward system architecture.
3Productivity
If real-time visualization is implemented, then defect detection efficiency is improved, but the processing requirements and system complexity increase
Solution Approach 1:
The patent performs preliminary signal processing and analysis during the ultrasonic scanning process itself. The processor continuously analyzes incoming ultrasonic signals in real-time, generating visual representations as the transducer moves across the material surface. This preliminary action enables immediate defect identification without requiring separate post-processing steps, thereby improving detection efficiency.
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 real-time, high-resolution visualization of defects in composite materials, overcoming limitations of traditional acoustic coupling methods and infrastructure requirements, allowing for efficient defect detection in complex structures.
Implementation Method 1
an ultrasonic transducer operable to emit ultrasonic waves into a test object and receive ultrasonic waves from the test object
Implementation Method 2
receive ultrasonic waves from the test object to produce scan data
Data Source
AI summary
The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system includes a graphical user interface (GUI) capable of showing a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. The GUI is capable of displaying the 3-D image as each additional 2-D cross section is scanned by an ultrasonic testing apparatus in real time or near real time, including probable defect regions that contain a flaw such as a hole, crack, wrinkle, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting defect areas within the 3-D image in real time or near real time and providing data regarding each defect area, such as the depth, size, and/or type of each defect.