Laser Bond Inspection System Using Target Patch
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Solution Overview
Problem
Conventional laser bond inspection systems face challenges in quickly and efficiently identifying testing sites on laminated parts and transmitting laser-induced stress waves, particularly due to the use of large inspection heads and the need for complex water delivery systems, which can cause water damage.
Innovation Solution
A laser bond inspection system utilizing a high-power and low-power laser beam, a target patch with ablative, tamping, and retro-reflective layers, and an adjustable beam-aiming optic to accurately direct the high-power laser beam to specific locations on the part, eliminating the need for free-flowing water and simplifying the inspection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional laser bond inspection systems use large inspection heads, then the laser beam can be transmitted to the part, but access to some locations on the laminated part becomes difficult
Solution Approach 1:
The inspection system is divided into separate functional components: a compact beam delivery unit, a separate focusing lens, and a target patch. This segmentation allows the main inspection head to be small and maneuverable, while the focusing lens can be positioned close to the target patch for precise beam delivery to difficult-to-reach locations.
Solution Approach 2:
A target patch is introduced as an intermediary element between the laser beam and the laminated part. The target patch includes a retro-reflective portion that facilitates precise beam positioning and a stress wave generating portion that transmits the laser energy to the part. This intermediary enables accurate beam delivery to hard-to-access areas without requiring a large inspection head.
2Reliability
If conventional laser bond inspection systems use flowing water to generate compression waves, then the laser-induced stress wave can be transmitted, but complex water delivery and containment measures are required and water damage issues are introduced
Solution Approach 1:
The water medium is completely removed from the inspection system. Instead of using flowing water to generate compression waves, the system uses direct laser irradiation of the target patch, which is in contact with the laminated part. The laser energy is transmitted through the target patch to generate stress waves directly in the part, eliminating the need for complex water delivery and containment systems while avoiding water damage risks.
Solution Approach 2:
The mechanical water delivery system is replaced with an optical system. The laser beam directly transmits energy through the target patch to generate stress waves in the laminated part, substituting the mechanical water-based stress wave generation method with a direct optical-mechanical energy transfer method that is simpler and eliminates water-related complications.
3Power
If the high-power laser beam is directly transmitted to the part, then stress waves can be generated, but surface damage may occur
Solution Approach 1:
The target patch serves as an intermediary between the high-power laser beam and the laminated part. The stress wave generating portion of the target patch is designed to efficiently convert laser energy into stress waves that propagate into the part, while the retro-reflective portion and overall structure minimize direct laser exposure and thermal damage to the part surface. This intermediary enables high-power laser transmission without causing surface damage.
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 efficient and accurate inspection of laminated parts, including difficult-to-reach locations, without the risk of water damage, by precisely targeting and transmitting stress waves to detect bond integrity while minimizing surface damage.
Implementation Method 1
The retro-reflective portion is configured to reflect the low-power laser beam
Implementation Method 2
The ablative portion is configured to absorb the high-power laser beam
Implementation Method 3
The ablative portion is configured to absorb the high-power laser beam
Implementation Method 4
The tamping portion is configured to allow transmission of the high-power laser beam through the tamping portion and to redirect energy absorbed by the ablative portion into the part
Data Source
AI summary
Disclosed herein is a laser bond inspection system that comprises a high-power laser, configured to generate a high-power laser beam having a high energy, and a low-power laser, configured to generate a low-power laser beam having a low energy that is less than the high energy. The laser bond inspection system further comprises a target patch. The laser bond inspection system additionally comprises a beam-aiming optic, configured to receive the low-power laser beam from the low-power laser and redirect the low-power laser beam at the target patch when the target patch is affixed to the part. The laser bond inspection system also comprises an optical sensor, configured to detect a reflected portion of the low-power laser beam reflected off of the target patch. The beam-aiming optic is further configured to receive the high-power laser beam from the high-power laser and redirect the high-power laser beam at the target patch.