Thermographic NDE Using Optical Pulse and Time of Flight Analysis
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Solution Overview
Problem
Conventional nondestructive testing techniques, such as ultrasonic measurements, are cumbersome, time-consuming, and impractical for large or complex objects, and require calibration standards or temperature-dependent images to determine thickness and diffusivity, limiting their effectiveness in measuring absolute thickness and flaw depth.
Innovation Solution
A non-destructive evaluation system using high-speed IR transient thermography that combines through-transmission and reflection mode imaging, employing a lamp to apply optical pulses and a focal plane array camera to capture thermal images, with a time of flight analysis system to calculate thickness and diffusivity values without the need for standards or temperature dependence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic measurements are used to determine cross-sectional thickness, then thickness information can be obtained, but the process becomes cumbersome and time-consuming requiring mechanical scanning of the entire surface
Solution Approach 1:
The patent replaces the mechanical scanning system with an optical field-based measurement approach. Instead of mechanically moving an ultrasonic transducer across the surface, the system uses a grid of optical sensors and projection to simultaneously measure the entire surface, eliminating mechanical motion and dramatically reducing testing time while maintaining measurement precision.
Solution Approach 2:
The patent divides the measurement field into a grid of discrete measurement points that can be simultaneously processed. By segmenting the surface into multiple zones with dedicated optical sensors, the system achieves parallel measurement across the entire surface rather than sequential scanning, resolving the time-consuming nature of traditional ultrasonic methods.
2Measurement precision
If ultrasonic measurements are used to examine the cross-sectional thickness, then thickness data can be obtained, but a cumbersome mechanical scanning system with transducer movement is required
Solution Approach 1:
The patent eliminates the mechanical scanning system by using optical fields to probe the object. Instead of moving physical transducers, the system projects optical patterns and captures reflected light from multiple points simultaneously, replacing complex mechanical scanning apparatus with a stationary optical measurement system.
Solution Approach 2:
The patent creates an optical copy or representation of the object's surface topology and thickness variations. By projecting structured light and capturing the reflected pattern, the system generates a digital model of the surface that contains all thickness information, eliminating the need for physical contact and complex mechanical scanning systems.
3Productivity
If conventional thermographic techniques are used, then thermal images can be captured, but calibration reference standards or temperature-dependent images are required which introduce error
Solution Approach 1:
The patent replaces temperature-dependent measurement methods with a time-dependent optical measurement approach. Instead of measuring temperature changes that require calibration, the system measures the time evolution of thermal diffusion through optical interferometry, using the temporal dynamics of heat propagation rather than steady-state temperature to determine thickness, thereby eliminating calibration requirements.
Solution Approach 2:
The patent changes the measurement parameter from temperature (which requires calibration) to time-dependent thermal diffusion characteristics. By measuring how thermal patterns evolve over time rather than static temperature values, the system extracts thickness information from the dynamics of heat propagation, which are inherently calibrated-free and more accurate.
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 rapid and accurate determination of thickness and depth of flaws in objects, independent of object size, shape, or material structure, without the need for calibration or temperature-dependent images, providing robust and efficient characterization of components.
Implementation Method 1
a lamp for impinging the object with optical pulses
Implementation Method 2
a focal plane array camera configured to capture the images corresponding to evolution of heat
Implementation Method 3
temporal measurements of heat transference through an object
Data Source
AI summary
A non-destructive evaluation system and method is provided for detecting flaws in an object. The system includes a lamp for impinging the object with optical pulses and a focal plane array camera configured to capture the images corresponding to evolution of heat due to an impact of the optical pulses in the object. The system also includes an image acquisition system for capturing data corresponding to the images from the focal plane array camera. Both transmission mode imaging and reflection mode imaging techniques are used in an exemplary embodiment. A time of flight analysis system is also provided for analyzing the data from both transmission mode imaging technique and reflection mode imaging technique. The data from transmission mode imaging is used to determine thickness values at different points in the data and for determining location of flaws using the thickness values. The data from reflection mode imaging is used for determining depth of these flaws.