Multi-Thickness Ultrasonic Reference Block for Shear Wave Calibration
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Solution Overview
Problem
The existing method for calibrating ultrasonic shear waves for inspecting metallic structures, particularly for non-accessible cracks from fastener holes in aircraft, requires multiple reference blocks for each thickness and fastener diameter, complicating maintenance and inspection tasks.
Innovation Solution
A generic reference block with multiple thicknesses and cavities, featuring slots at the edges, allows for calibration across various thicknesses and fastener diameters, reducing the need for multiple blocks by simulating different hole diameters and edge change-over patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple reference blocks are manufactured for each thickness and fastener diameter, then calibration accuracy for specific parts is improved, but the number of reference blocks and device complexity increases
Solution Approach 1:
The reference block is designed with multiple cavities of different thicknesses and different slot configurations that simulate various fastener hole diameters. This allows a single reference block to serve multiple calibration purposes that previously required separate blocks for each thickness and fastener diameter combination, thereby reducing the total number of reference blocks needed while maintaining calibration accuracy across different part specifications
Solution Approach 2:
The reference block is divided into multiple cavities, each cavity containing slots that simulate cracks at different distances from fastener hole edges. This segmentation allows the single block to represent multiple calibration scenarios (different thicknesses and fastener diameters) through its various cavity-slot combinations, enabling one block to replace many specialized blocks
2Adaptability or versatility
If multiple reference blocks are maintained for different specifications, then calibration coverage is improved, but storage and maintenance costs increase
Solution Approach 1:
By designing the reference block with multiple cavities representing different thicknesses and slot configurations representing different fastener diameters, a single universal reference block provides calibration coverage for multiple part specifications. This eliminates the need to manufacture, store, and maintain multiple specialized reference blocks, thereby reducing storage space requirements and associated maintenance costs while preserving comprehensive calibration coverage
3Loss of energy
If a gap is introduced between the block and working surface, then ultrasonic energy loss is reduced, but manufacturing complexity increases
Solution Approach 1:
Instead of creating a horizontal gap between the reference block and the working surface, the invention introduces a vertical dimension by elevating the block on supports. This dimensional change achieves the same goal of preventing ultrasonic energy loss through contact with the working surface while maintaining simple block geometry that is easy to manufacture. The supports provide the necessary elevation without complicating the block's core structure
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 solution simplifies the calibration process, reduces manufacturing and storage costs, and speeds up inspection procedures by allowing a single reference block to substitute for multiple conventional blocks, thereby streamlining maintenance and inspection tasks.
Implementation Method 1
An ultrasound method using shear waves technique is currently applied. This method comprises using an ultrasound device (instrument and probe) that introduces an ultrasound beam through the accessible surface of the component
Implementation Method 2
If a crack exists, the ultrasound beam rebounds against it and comes back to the device
Implementation Method 3
An ultrasound method using shear waves technique is currently applied
Implementation Method 4
the ultrasound beam rebounds against it and comes back to the device. The device can be adjusted to relate the signal received to the position and size of the crack
Data Source
AI summary
A reference block for ultrasonic shear waves calibration, comprising slots, wherein the reference block has at least two different thicknesses, each thickness comprising two cavities with at least one slot being provided at each cavity. Preferably, the reference block comprises a plurality of steps, each step defining a different thickness.