Ion Beam Joint Inspection System

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Solution Overview

Problem

Conventional non-destructive inspection methods, such as X-rays and ultrasound, are inadequate for detecting voids or unbonded sections in welds or bonded joints due to limited penetration, low depth resolution, and sensitivity issues, especially in dense materials and large structures.

Innovation Solution

A joint inspection system utilizing an ion beam source to create acoustic pulses at specific depths within a structure, with an acoustic sensor measuring travel time and magnitude to identify inconsistencies, and optionally adjusting kinetic energy and using a beam-steering system to enhance sensitivity and resolution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional non-destructive inspection methods (X-rays, ultrasound) are used to inspect joints, then the inspection process is simple and non-invasive, but the detection sensitivity and depth resolution are insufficient for detecting voids in welds or unbonded sections in dense materials

Engineering Contradiction:

Improvedetection sensitivityVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary substance (couplant) between the acoustic sensor and the structure surface to improve acoustic energy transmission. This couplant mediates the interaction between the sensor and the dense material, enabling better detection of internal joint inconsistencies that would otherwise be undetectable due to the density barrier

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The inspection process is segmented into multiple stages: positioning the structure, applying couplant, sending ion beams to create acoustic pulses, sensing acoustic energy transmission, and analyzing results. This segmentation allows each step to be optimized independently, improving overall detection precision while managing system complexity

Inventive Principle:

Principle #1Segmentation

2Length of stationary object

If ion beam energy is increased to improve penetration depth for inspecting thicker structures, then the Bragg peak depth increases, but the kinetic energy required increases significantly

Engineering Contradiction:

Improveinspection depthVSAvoidkinetic energy consumption

Core Design Contradiction:

Length of stationary objectVSUse of energy by moving object

Solution Approach 1:

The patent changes the parameter of ion beam kinetic energy to control the Bragg peak depth, allowing inspection at different depths within the structure. By adjusting this parameter, the system can inspect thicker structures while managing energy consumption through optimized beam parameters rather than simply increasing energy linearly with depth

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If the structure is placed under tension to improve detection of unbonded sections, then the sensitivity to joint inconsistencies increases, but the risk of causing damage to the structure increases

Engineering Contradiction:

Improvejoint inconsistency detectionVSAvoidstructural damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent applies partial tension (controlled stress) to the structure during inspection to enhance the detection of unbonded sections. By applying only the necessary amount of tension to improve sensitivity rather than excessive force, the system achieves better detection precision while minimizing the risk of causing structural damage

Inventive Principle:

Principle #16Partial or excessive action

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 provides effective detection of inconsistencies in joints by generating acoustic pulses at precise depths, offering superior sensitivity and resolution compared to conventional methods, capable of inspecting thicker structures and verifying bond strength without destructive testing.

Implementation Method 1

An ion beam is sent, by an ion beam source, into a first surface of the structure to form an acoustic pulse source in the structure at a depth corresponding to a Bragg peak of the ion beam

Methodology Applied

Scientific EffectBragg peak:

Implementation Method 2

The kinetic energy of ions in the ion beam can be controlled to adjust the depth of the acoustic pulse source

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

A travel time and a magnitude of an acoustic pulse generated by the acoustic pulse source is sensed, by an acoustic sensor positioned at a second surface of the structure

Methodology Applied

Scientific EffectAcoustic pulse propagation: Sound

Data Source

PatentEP3767288B1Joint inspection system and methods of inspecting a joint in a structure

Publication Date: 2024.01.31 THE BOEING CO

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AI summary

A joint inspection system and methods of inspecting a joint in a structure are presented. In a method, an ion beam is sent, by an ion beam source, into a first surface of the structure to form an acoustic pulse source in the structure at a depth corresponding to a Bragg peak of the ion beam, wherein acoustic pulse source is adjacent to the joint. A travel time and a magnitude of an acoustic pulse generated by the acoustic pulse source is sensed, by an acoustic sensor positioned at a second surface of the structure, to thereby form a response, wherein the joint is between the acoustic pulse source and the second surface.