Flash and Flowing Thermography for Component Defect Detection
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Solution Overview
Problem
Current nondestructive testing methods for components, such as gas turbine engine components, are inadequate in detecting defects, particularly in deeper regions and smaller defects, due to limitations in existing thermographic techniques.
Innovation Solution
A method and system combining flash thermography and flowing thermography, utilizing a flash lamp, infrared camera, and fluid supply to capture comprehensive 2D images of components, enabling detection of surface, near-surface, and deeper defects by creating larger thermal gradients through internal fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing thermographic techniques are used, then inspection can be performed, but defect detection depth and precision are insufficient
Solution Approach 1:
The patent combines flash thermography and flowing thermography into a single integrated inspection system. The flash lamp provides external heating while fluid flows through internal passages, creating complementary thermal gradients that enhance defect detection capability throughout the component volume.
Solution Approach 2:
The system utilizes temperature as a key parameter by applying thermal energy through both flash heating and fluid flow. Thermal gradients are created and monitored to detect defects, changing the thermal state of the component to reveal subsurface anomalies that would not be visible at ambient conditions.
2Measurement precision
If multiple inspection methods are used to improve defect detection, then detection capability improves, but inspection time increases
Solution Approach 1:
By merging flash and flowing thermography into one simultaneous inspection process, the system achieves comprehensive defect detection without requiring separate inspection steps. The dual heating mechanisms operate together to provide information about different defect types and locations in a single test sequence.
Solution Approach 2:
The inspection process maintains continuous thermal stimulation and monitoring, with fluid flowing continuously through the component while the infrared camera continuously captures thermal data. This eliminates idle time between discrete inspection steps and maintains optimal detection conditions throughout the process.
3Area of stationary object
If comprehensive 2D images covering 360 degrees are captured, then defect detection coverage improves, but system complexity increases
Solution Approach 1:
The inspection system is designed to perform multiple functions: flash heating, fluid flow through internal passages, infrared imaging, and 360-degree rotation. A single integrated system accomplishes all these tasks, avoiding the need for multiple separate inspection devices and reducing overall system complexity.
Solution Approach 2:
The system adds rotational movement to achieve 360-degree inspection coverage, transforming a single-view inspection into a multi-angular comprehensive examination. This dimensional addition allows detection of defects on all surfaces and internal passages without requiring multiple fixed inspection positions.
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
Enhances defect detection depth and size assessment, reducing inspection time and technician fatigue by providing composite 2D images that cover 360 degrees of the component, effectively identifying disbonds, blocked cooling passages, inclusions, cracks, porosity, and other defects.
Implementation Method 1
flashing the component using a flash lamp configured for flash thermography
Implementation Method 2
collecting first image data regarding the component using an infrared camera
Implementation Method 3
flowing a fluid through the component
Data Source
AI summary
In some examples, a method for nondestructive testing of a component may include flashing the component using a flash lamp configured for flash thermography, collecting first image data regarding the component using an infrared camera, flowing a fluid through the component, and collecting second image data regarding the component using the infrared camera. A system for nondestructive testing of a component may include a single inspection station and a flash lamp configured for flash thermography, means for supplying a fluid to the component, and an infrared camera disposed at the inspection station.