Non-destructive Testing of Mechanical Parts Using Ray-Tracing Filtering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current non-destructive testing methods using ultrasonic waves struggle with accurately characterizing the integrity of mechanical parts with complex shapes and varying interfaces between the transducer and the part, as they rely on assumptions of direct contact and flat interfaces, limiting their effectiveness in detecting defects in aeronautical parts like titanium alloy billets and impellers.
Innovation Solution
A digital filtering technique using a multi-element transducer that employs a ray-tracing algorithm to calculate the single scattering sub-space, allowing for accurate propagation time calculations and filtering of ultrasonic signals regardless of the part's shape or interface, enabling effective defect detection by projecting frequency components onto a numerically determined single scattering sub-space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a theoretical estimate of the single scattering sub-space is used based on direct contact and flat interface assumptions, then the filtering process is simplified, but the accuracy of defect detection deteriorates for parts with complex shapes and varying interfaces
Solution Approach 1:
The patent replaces the theoretical/mathematical model (based on flat interface assumptions) with a numerical simulation model (ray-tracing algorithm) that can handle complex geometries. This substitution allows the system to maintain filtering capability while accurately representing the physical reality of complex-shaped parts with varying interfaces.
Solution Approach 2:
The patent changes the fundamental parameter of the sub-space determination from theoretical estimates (based on simplified assumptions) to numerically calculated values (based on actual geometry). This parameter change enables the system to adapt to different part shapes and interface configurations while maintaining detection accuracy.
2Reliability
If direct contact between transducer and mechanical part is required, then the theoretical model assumptions are satisfied, but the ease of operation and applicability to complex shapes deteriorates
Solution Approach 1:
The patent replaces the mechanical contact requirement with a numerical simulation approach. The ray-tracing algorithm can model ultrasonic wave propagation through complex geometries without requiring physical contact, thereby maintaining model validity while significantly improving ease of operation.
Solution Approach 2:
The patent introduces a numerical simulation model as an intermediary between the transducer and the mechanical part. This intermediary allows the system to account for complex geometries and interface variations without requiring direct contact, bridging the gap between theoretical assumptions and practical application.
3Measurement precision
If digital filtering is applied to reduce noise and multiple scattering components, then the signal quality improves, but the device complexity and computational requirements increase
Solution Approach 1:
The patent performs preliminary calculation of the single scattering sub-space using ray-tracing simulations before the actual filtering operation. This preliminary action prepares the numerical model in advance, allowing the subsequent filtering process to proceed more efficiently with reduced computational burden during actual testing.
Solution Approach 2:
The patent creates a numerical copy (virtual model) of the ultrasonic wave propagation through the mechanical part using ray-tracing. This copy allows the system to simulate and analyze wave behavior without requiring complex physical filtering apparatus, thereby improving signal quality while managing device complexity.
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 improves the quality of non-destructive testing by reducing noise and enhancing defect detection accuracy for complex-shaped mechanical parts, allowing for inspection without direct contact and regardless of the part's shape or interface configuration, thus facilitating more effective and rapid testing.
Implementation Method 1
a transducer (i.e. a sensor) composed of multiple piezoelectric element capable of emitting and of receiving ultrasonic waves
Implementation Method 2
ultrasonic waves are emitted by the multi-element transducer at a predetermined frequency, and interact with the microstructure of the material of the part
Implementation Method 3
a so-called single scattering component, representing the wave trajectories where the wave propagated in the part interacts only once with the material of the part
Implementation Method 4
possibly a so-called multiple scattering component, representing the wave trajectories where the wave propagated in the mechanical part interacts several times with the material of the mechanical part
Data Source
AI summary
A method for non-destructive testing of a mechanical part by a multi-element transducer having piezoelectric elements, where:for each element e(i) of the transducer, the emission of an ultrasonic wave at a given frequency and measurement, by each element e(j) distinct from the element e(i), of a time-varying signal kij(t) representing the back-scattered ultrasonic wave received by the element e(j);the determination of a first matrix of time-varying components based on measured signals kij(t), i, j=1, . . . , N;the determination of a second matrix of frequency components corresponding to a determined frequency based on the frequency of the ultrasonic wave by applying a Fourier transform to said first matrix;the filtering of said second matrix comprising a projection of it onto a single scattering sub-space determined by means of a numerical calculation using a ray tracing algorithm; andthe verification of the integrity of the mechanical part by using said filtered second matrix.