Phased Array Ultrasonic Inspection for Surface Hardening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultrasonic goniometers require complex mechanical constructions to specify the angle of incidence, which are inflexible and lack precision, especially for high-accuracy measurements, and fail to effectively detect depth-dependent changes in material properties and defects post-surface hardening processes like shot peening.
Innovation Solution
The method employs an ultrasonic phased array to irradiate and detect ultrasonic waves at a definable angle without mechanical adjustments, using frequency- and time-resolved detection to determine the phase shift and frequency-dependent propagation speed of guided waves, enabling flexible and accurate characterization of component properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical constructions are used to specify the angle of incidence, then the device structure is simple, but the measurement precision and flexibility are insufficient
Solution Approach 1:
The patent replaces the conventional mechanical system for specifying the angle of incidence with an ultrasonic phased array system. Instead of mechanically adjusting transducer positions and orientations, the invention uses electronic phase control of multiple ultrasonic elements to achieve precise angle specification. The phased array electronically steers the ultrasonic beam at defined angles without any mechanical movement, thereby eliminating mechanical complexity while achieving high measurement precision.
Solution Approach 2:
The invention changes the control parameter from mechanical position/orientation to electronic phase difference. By controlling the phase difference between adjacent ultrasonic elements, the system can electronically adjust the angle of incidence with high precision. This parameter change enables flexible and accurate angle specification without the constraints of mechanical systems.
2Adaptability or versatility
If mechanical constructions with pivot points and rails are used, then the device can be manufactured, but the flexibility and precision for high-accuracy measurements are limited
Solution Approach 1:
The patent eliminates mechanical pivot points, rails, and bearings by using an entirely electronic phased array system. The ultrasonic beam direction is controlled through electronic phase modulation rather than mechanical positioning. This substitution provides unlimited flexibility in adjusting the angle of incidence and eliminates the manufacturing precision limitations inherent in mechanical systems.
Solution Approach 2:
The invention transforms the static mechanical positioning system into a dynamic electronic control system. The phased array can rapidly and continuously adjust the angle of incidence by changing phase differences, providing dynamic adaptability that mechanical systems cannot achieve. This enables flexible measurement of components at various angles without reconfiguring mechanical components.
3Reliability
If conventional goniometer arrangements are used, then the basic measurement function is achieved, but the detection of depth-dependent changes and defects post-surface hardening is insufficient
Solution Approach 1:
The patent segments the ultrasonic detection into multiple phased array elements that can independently control and detect ultrasonic waves at different angles and depths. By dividing the detection function across multiple elements, the system can simultaneously measure surface properties and depth-dependent material characteristics, including defects introduced by surface hardening processes like shot peening.
Solution Approach 2:
The invention adds the dimension of depth resolution to the conventional surface measurement function. The phased array configuration enables the system to probe at different penetration depths by adjusting the excitation parameters, thereby detecting both surface conditions and subsurface defects in three-dimensional space rather than just at the surface.
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 approach allows for non-destructive, non-contact testing with improved accuracy and flexibility, effectively detecting changes in material properties and residual stresses post-surface hardening, such as shot peening, by varying the angle of incidence and analyzing the frequency-dependent propagation speed of ultrasonic waves.
Implementation Method 1
ultrasonic waves that are radiated onto the component surface at a non-perpendicular angle of incidence
Implementation Method 2
the intensity of the ultrasonic waves reflected on the surface of the component is recorded
Implementation Method 3
the frequency dependency of the propagation speed of the ultrasonic waves guided on the surface of the component can be determined
Implementation Method 4
ultrasonic waves guided on the surface of the component
Data Source
AI summary
The invention relates to a method for the destruction-free and contactless inspection of components (3), in which ultrasound waves (6) are transmitted in a non-vertical, pre-specifiable incidence angle (9) onto the surface of the component (3) using an ultrasound transmission transducer (1) arranged at a distance from the surface of the component (3) and the intensity of the ultrasound waves (7), which are reflected by the surface of the component (3), is captured in a time-resolved and/or frequency-resolved manner by the group antenna elements (2n) of an ultrasound group antenna (2), which is configured to detect ultrasound waves (7), and, on this basis, the phase shift of the ultrasound waves, which are guided on the surface of the inspection body, is determined in relation to the ultrasound waves (7), which are reflected directly at the surface of the component (3).