Porosity Inspection for Composite Structures with Non-Parallel Surfaces
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Solution Overview
Problem
Current ultrasound testing methods for porosity in composite structures are time-consuming and labor-intensive, especially when dealing with cross-sections having non-parallel surfaces, leading to increased inspection times and costs due to the need for manual analysis and potential over-rejection of acceptable materials.
Innovation Solution
An ultrasound inspection system that identifies a thickness profile of a composite structure's region with non-parallel surfaces, estimates thickness at specific locations, and uses attenuation data to determine porosity, thereby generating indications of undesirable porosity and reducing the need for extensive manual evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasound testing is performed on the entire surface of the composite structure to ensure accurate porosity detection, then measurement precision is improved, but loss of time and productivity deteriorate
Solution Approach 1:
The system applies local quality by creating a thickness profile that divides the composite structure into regions with different thickness characteristics. Instead of uniformly inspecting the entire surface, the system identifies specific locations with non-parallel surfaces that require detailed inspection, while other areas can be inspected with reduced effort or skipped entirely. This localized approach maintains detection accuracy where needed while reducing overall inspection time.
Solution Approach 2:
The inspection system segments the composite structure inspection process into distinct phases: first acquiring a thickness profile of the entire structure, then identifying specific regions of interest with non-parallel surfaces, and finally performing detailed ultrasound inspection only on those identified regions. This segmentation allows the system to maintain high measurement precision for critical areas while significantly reducing the total inspection time by excluding areas that do not require detailed examination.
2Measurement precision
If manual analysis is performed on all ultrasound data from the entire surface, then measurement precision is improved, but device complexity and ease of operation worsen
Solution Approach 1:
The system performs preliminary action by automatically generating a thickness profile and identifying regions with non-parallel surfaces before the detailed porosity inspection. This preliminary analysis creates a map of areas that require detailed examination, allowing the system to focus manual or automated analysis resources on specific locations rather than requiring manual analysis of all ultrasound data from the entire surface. This reduces the operational complexity while maintaining measurement precision.
Solution Approach 2:
The thickness profile acts as an intermediary that bridges the gap between the complex ultrasound data acquisition process and the simpler porosity evaluation process. By first creating this intermediate representation of the structure's geometry, the system simplifies the subsequent inspection process, automatically identifying which regions need detailed analysis without requiring operators to manually evaluate all ultrasound data points.
3Measurement precision
If ultrasound testing is performed on regions with non-parallel surfaces using traditional methods, then measurement precision is maintained, but loss of time and productivity worsen
Solution Approach 1:
The system applies local quality by creating a thickness profile that divides the composite structure into regions with different thickness characteristics. Instead of uniformly inspecting the entire surface, the system identifies specific locations with non-parallel surfaces that require detailed inspection, while other areas can be inspected with reduced effort or skipped entirely. This localized approach maintains detection accuracy where needed while reducing overall inspection time.
Solution Approach 2:
The system employs dynamics by adaptively adjusting the inspection strategy based on the identified thickness profile. Rather than using a static, uniform inspection approach across the entire structure, the system dynamically determines which regions require detailed ultrasound inspection based on their geometric characteristics. This dynamic adaptation allows the system to maintain high productivity by focusing resources on challenging regions while efficiently processing or skipping simpler areas.
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 quicker and more efficient porosity evaluation, reducing the likelihood of rejecting acceptable materials and minimizing the time and cost associated with inspecting composite structures, while ensuring accurate detection of porosity levels.
Implementation Method 1
an ultrasound system may perform ultrasound testing to gather data from all of the surfaces of each composite structure
Implementation Method 2
information about attenuation of response sound signals
Data Source
AI summary
A method and apparatus for inspecting a composite structure. A thickness profile of a portion of a region of a composite structure is identified. The region has a cross-section with non-parallel surfaces. An estimated thickness for a location within the region and outside of the portion is identified using the thickness profile. An indication of whether the location has undesirable porosity is generated based on information about attenuation of response sound signals and the estimated thickness for the location.