Ultrasonic Detection for Composite Parts with Complex Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultrasonic testing methods for composite material parts with complex profiles and structures face challenges in achieving accurate testing due to significant acoustic attenuation and the lack of suitable reference blocks, leading to inaccurate DAC curves and testing blind areas.
Innovation Solution
The method involves preparing angled reference blocks with varying inclination angles matching those of the composite material part, determining acoustic attenuation, correcting the DAC curve, and optimizing incident and receiving angles for both reflection and penetration methods to improve testing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic testing methods are used on composite material parts with complex profiles, then the testing process is simple, but the testing accuracy deteriorates due to significant acoustic attenuation and lack of suitable reference blocks
Solution Approach 1:
The patent divides the complex profile into multiple inclined surface sections, each with different inclination angles. Multiple angled reference blocks are prepared, each corresponding to a specific inclination angle range. This segmentation allows the testing method to be simplified for each section while maintaining overall accuracy by compensating for acoustic attenuation specific to each inclination angle.
Solution Approach 2:
The patent changes the inclination angle parameter of reference blocks to match different sections of the complex profile. By preparing reference blocks with specific inclination angles (minimum, maximum, and intermediate values), the method adapts the testing parameters to the geometric characteristics of each section, thereby improving measurement precision without requiring a completely complex testing system.
2Measurement precision
If angled reference blocks with multiple inclination angles are prepared to improve testing accuracy, then the testing precision improves, but the preparation complexity and time increase
Solution Approach 1:
Instead of preparing reference blocks for all possible inclination angles, the patent identifies and prepares reference blocks only for critical inclination angles (minimum, maximum, and intermediate values) that represent different sections of the complex profile. This local quality approach ensures adequate coverage for DAC curve correction while significantly reducing the number of reference blocks needed compared to a exhaustive approach.
3Reliability
If multiple testing methods (reflection and penetration) with optimized angles are used, then the reliability of testing improves, but the testing process complexity increases
Solution Approach 1:
The patent employs dynamic selection of testing methods (reflection or penetration) and incident angles based on the specific inclination angle of each inclined surface section. The method adapts the testing approach to match the local geometric characteristics, optimizing reliability for each section. This dynamic adaptation is guided by predetermined angle ranges, which simplifies the operation by providing clear decision criteria for method selection.
4Measurement precision
If acoustic attenuation compensation is implemented through DAC curve correction, then the measurement precision improves, but the calculation and processing complexity increases
Solution Approach 1:
The patent performs preliminary acoustic attenuation compensation by constructing corrected DAC curves using reference blocks with known inclination angles before actual defect detection. The attenuation characteristics are determined in advance for each inclination angle section, and the DAC curves are pre-corrected. This preliminary action simplifies the actual testing process, as the compensation parameters are already established and only need to be applied during defect detection.
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
This approach enhances the accuracy of ultrasonic testing for composite material parts with complex profiles by compensating for acoustic attenuation and optimizing testing parameters, thereby reducing testing blind areas and improving reliability.
Implementation Method 1
ultrasonic testing refers to a non-destructive testing method for testing an internal structure and defects of the material by means of ultrasonic waves
Implementation Method 2
determining acoustic attenuation caused by corresponding inclination angles based on the plurality of angled reference blocks
Implementation Method 3
measuring a bottom echo, and adjusting an echo height to 80% of a full screen height
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The purpose of the present disclosure is to provide an ultrasonic detection method for a composite material part, comprising the following steps: using the same material and preparation process as a part to be detected to prepare comparison test blocks of multiple angles; determining the sound attenuation caused by a corresponding tilt angle according to the comparison test blocks of multiple angles, so as to obtain a compensation DAC correction curve; obtaining the best incident angle detected by a reflection method, the best incident angle detected by a penetration method, and the best reception angle detected by the penetration method; detecting the part by using the penetration method, and then detecting the part for a second time by using the reflection method. When detecting the slope, the detection sensitivity is adjusted according to the DAC correction curve. The ultrasonic detection method for a composite material part can improve the accuracy of performing detection on parts with complex shapes and structures.