Composite Wrinkle Reference Standard for Non-Destructive Inspection
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Solution Overview
Problem
Current inspection methods for composite components often require physical destruction to assess sub-surface irregularities, such as wrinkles, which are not feasible for preserving the components.
Innovation Solution
The development of non-destructive inspection reference standards, created by imparting predetermined non-planar characteristics onto composite materials using a tool with specific surface features, allowing for the calibration of wrinkle measurement systems and evaluation of composite parts without damaging them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If physical inspection of cross-section is used to detect sub-surface irregularities, then detection capability is improved, but the composite component is destroyed
Solution Approach 1:
The patent creates a reference standard that is a copy of a composite component with known sub-surface irregularities. This reference standard can be physically inspected without affecting the actual components being evaluated. The copying principle allows the inspection methodology to be validated on a duplicate specimen while preserving the original components for continued use.
2Reliability
If non-destructive inspection methods are used to preserve composite components, then component retention is improved, but the ability to accurately assess sub-surface irregularities deteriorates
Solution Approach 1:
The patent applies preliminary action by creating a reference standard with known irregularities before actual inspection tasks. This pre-prepared reference standard establishes a baseline for comparison that enables accurate assessment of sub-surface features using non-destructive methods on actual components. The preliminary creation of the reference standard with controlled defects allows validation of inspection techniques without compromising component integrity.
Solution Approach 2:
The patent utilizes parameter changes by varying the physical and chemical properties of composite materials during the reference standard creation process. Different curing conditions, material compositions, and processing parameters are employed to create reference standards with specific, known irregularities. These parameter variations enable the establishment of a comprehensive reference library that covers a range of potential defects while maintaining component usability.
3Reliability
If composite components with sub-surface irregularities are discarded to ensure quality, then quality control is improved, but material loss increases
Solution Approach 1:
The patent replaces the mechanical destruction method (physical cross-section inspection) with a non-destructive inspection approach using reference standards. Instead of mechanically cutting and examining components, the system uses comparative analysis against reference standards with known characteristics. This substitution eliminates material loss while maintaining quality control through accurate defect assessment.
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 non-destructive evaluation of composite components, allowing for the retention and use of parts that would otherwise be discarded due to sub-surface anomalies, by using calibrated reference standards to assess and validate the presence and degree of non-planar characteristics.
Implementation Method 1
applying a first charge to the tool first surface; at least partially curing the first charge, with the first charge comprising a first charge first surface and a first charge second surface
Data Source
Figure 1
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Figure 5A~5B
AI summary
Methods, systems and components made according to the methods and systems, are disclosed relating to making inspection reference standards for the non-invasive inspection of composite materials.