X-ray Inspection of Turbine Passages Using Foam-Particulate Contrast
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Solution Overview
Problem
Conventional non-destructive testing methods struggle to effectively inspect internal features of components, particularly those with complex geometries or overlapping passages, such as gas turbine engine components, due to limited contrast and difficulty in distinguishing fine features within dense materials like aluminum and nickel-based alloys.
Innovation Solution
Introducing a mixture of expanding foam and high-density particulate material into the region of interest, which provides enhanced contrast through x-ray imaging, allowing for three-dimensional reconstruction and comparison with a model, facilitating the inspection of internal cavities and passages using x-ray sources and detectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional non-destructive testing methods are used to inspect internal features of components, then the inspection process is simple, but the contrast and visibility of internal features are insufficient
Solution Approach 1:
The patent introduces an intermediary substance (contrast agent or particulate material) into the internal cavities and passages of the component. This intermediary material provides radiographic contrast, enabling clear visualization of internal features that would otherwise be indistinguishable. The contrast agent acts as a mediator between the x-ray imaging system and the internal geometry, solving the visibility problem without requiring complex modifications to the component itself.
Solution Approach 2:
The patent changes the radiographic parameters by introducing materials with different attenuation coefficients into the internal passages. By modifying the density and composition of the material within the cavities (from air to contrast agent or particulate suspension), the radiographic contrast is significantly enhanced, allowing detailed inspection of internal features while maintaining a relatively simple inspection process.
2Measurement precision
If high-density particulate material is introduced into internal passages to enhance contrast, then the visibility of internal features improves, but the complexity of the inspection process increases
Solution Approach 1:
The patent utilizes pneumatic or hydraulic principles to introduce the particulate material into the internal passages. By applying pressure differential or fluid flow, the particulate suspension is delivered through injection ports or openings into the cavities and passages. This approach simplifies the material introduction process compared to manual methods, reducing operational complexity while achieving uniform distribution of the contrast-enhancing particulate material.
3Measurement precision
If expanding foam is used to distribute particulate material within internal cavities, then the coverage and contrast enhancement improve, but the time required for the inspection process increases
Solution Approach 1:
The patent employs phase transition of the foam material to achieve rapid and uniform distribution of particulate material within internal cavities. The foam is introduced in a liquid or low-viscosity state, then undergoes rapid expansion to a gaseous or cellular phase, filling the cavities and passages uniformly. This phase transition mechanism enables quick coverage of complex geometries without requiring extended waiting times, thus reducing the overall inspection time while maintaining excellent distribution uniformity.
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 method enhances the visibility of internal features, enabling more accurate inspection and evaluation of complex components by increasing contrast and allowing for the detection of small details within dense materials, improving the ability to discern dimensional attributes and manufacturing artifacts.
Implementation Method 1
acquiring image data of the object and particulate mixture using an x-ray source and an x-ray detector. The particulate has a density that is greater than the density of a material forming the object to provide contrast between the region of interest and the object in an image generated using the image data
Implementation Method 2
The first material can have a mass attenuation coefficient that is greater than a mass attenuation coefficient of the second material. The expanding foam can have a mass attenuation coefficient that is less than a mass attenuation coefficient of the second material
Implementation Method 3
introducing a mixture of expanding foam and a particulate material into a region of interest of an object, fixing the powder within the region of the interest relative to the object
Data Source
AI summary
An inspection method include introducing a mixture of expanding foam and a particulate material into a region of interest of an object, fixing the powder within the region of the interest relative to the object, and acquiring image data of the object and particulate mixture using an x-ray source and an x-ray detector. The particulate has a density that is greater than the density of a material forming the object to provide contrast between the region of interest and the object in an image generated using the image data.