Computed Tomography Porosity Standards for Composite Inspection
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Solution Overview
Problem
Current methods for establishing nondestructive inspection standards for porosity in composite materials are time-consuming, costly, and lack accuracy, often requiring extensive sample preparation and estimation of porosity based on limited data.
Innovation Solution
A method using computed tomography to create and identify porosity standards by forming samples with varying porosity levels through different curing techniques, generating three-dimensional images, and extracting volumetric data to establish precise porosity standards for nondestructive inspection systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional methods are used to form and analyze porosity standards, then sample preparation can be completed, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces mechanical sample preparation operations (sanding, polishing, cutting) with computed tomography scanning. Instead of physically preparing samples to reveal porosity, the CT system directly images the internal structure, eliminating time-consuming mechanical operations while providing accurate three-dimensional porosity data.
Solution Approach 2:
The patent creates a digital three-dimensional copy of the sample's internal structure through CT scanning. This virtual model allows for precise porosity measurement without requiring physical sample preparation or destruction, enabling repeated analysis of the same sample without additional preparation time.
2Productivity
If traditional estimation methods are used for porosity analysis, then porosity levels can be determined, but accuracy is insufficient
Solution Approach 1:
The patent transitions from two-dimensional surface estimation methods to three-dimensional volumetric analysis using CT scanning. This dimensional change enables accurate measurement of porosity throughout the entire sample volume, providing comprehensive and precise porosity data that cannot be obtained through surface-based estimation techniques.
Solution Approach 2:
The patent replaces manual estimation methods (based on height and weight measurements) with automated CT-based volumetric analysis. The system automatically segments pores from the sample matrix and calculates porosity, eliminating human subjectivity and improving measurement accuracy and repeatability.
3Measurement precision
If extensive sample preparation operations are performed, then samples can be prepared for testing, but operational complexity increases
Solution Approach 1:
The patent replaces complex mechanical sample preparation operations with a single CT scanning operation. Instead of performing multiple sequential operations (sanding, polishing, cutting, mounting), the system uses non-contact X-ray imaging to directly obtain three-dimensional porosity data, dramatically simplifying the workflow.
Solution Approach 2:
The CT scanning system performs self-alignment and automatic segmentation of porosity features without requiring manual intervention for sample positioning or analysis. The automated image processing algorithms independently identify and measure pores, reducing the need for operator skill and simplifying operations.
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 allows for quicker, more accurate, and cost-effective establishment of porosity standards, enabling more precise evaluation of composite materials with reduced sample size and operational complexity.
Implementation Method 1
A porosity level is identified for each sample in the plurality of samples using volumetric data extracted from a three-dimensional image for each sample generated using a computed tomography system
Data Source
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AI summary
A method and apparatus for establishing nondestructive inspection (106) porosity standards. In one illustrative embodiment, a plurality of samples (112) is formed using a different technique for each sample in the plurality of samples (112) such that each sample in the plurality of samples (112) has a different porosity from other samples in the plurality of samples (112). Each sample in the plurality of samples has a same set of selected properties as a selected part type (104). A porosity level is identified for each sample using volumetric data (148) extracted from a three-dimensional image (136) for each sample generated using a computed tomography system (132). A group of standards (102) is established for a group of selected porosity levels (156) from the plurality of samples (112) based on the porosity level identified for each sample in the plurality of samples (112). The group of standards (102) is configured for use in performing nondestructive inspection (106) of a part (108) of the selected part type (104).