In-situ Ultrasonic Monitoring for Composite Failure Detection

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Solution Overview

Problem

Current methods fail to accurately detect the initiation of structural failure in composite materials under load due to limitations in load-displacement curve analysis and require manual inspection, leading to inefficiencies and safety concerns during mechanical testing.

Innovation Solution

In-situ monitoring system with ultrasonic testing transducers mounted on the composite workpiece, allowing for continuous data acquisition and analysis during mechanical loading, enabling detection of failure initiation and growth without manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual ultrasonic inspection is performed during mechanical testing, then personnel safety is compromised, but automated in-situ monitoring resolves this by mounting transducers directly on the workpiece

Engineering Contradiction:

Improvepersonnel safetyVSAvoidmanual inspection requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The ultrasonic transducers are mounted directly on the composite workpiece and automatically perform inspection during mechanical loading without requiring manual intervention. The system monitors itself continuously as the load is applied, eliminating the need for operators to manually position transducers during critical testing phases.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The transducers are pre-mounted on the workpiece before mechanical loading begins. This preliminary positioning ensures that inspection is already in place and can immediately detect failure initiation as loads are applied, rather than requiring post-loading manual inspection.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If load is removed for manual inspection, then testing efficiency decreases, but continuous automated monitoring maintains testing progress

Engineering Contradiction:

Improvetesting efficiencyVSAvoididle time between inspections

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The ultrasonic transducers continuously monitor the composite workpiece throughout the entire mechanical loading process without interruption. Data is acquired continuously as loads are applied, eliminating idle time where the test machine must stop for manual inspections and allowing the testing process to proceed without breaks.

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If automated in-situ monitoring is implemented, then measurement precision and sensitivity improve, but device complexity increases

Engineering Contradiction:

Improvefailure detection accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The manual mechanical inspection process is replaced with an automated ultrasonic monitoring system. Transducers mounted on the workpiece automatically emit and receive ultrasonic waves, and a computer system processes the signals to detect failure initiation, replacing the need for manual operator intervention and subjective assessment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If traditional load-displacement curve analysis is used, then simplicity is maintained, but ability to detect failure initiation is insufficient

Engineering Contradiction:

Improvemonitoring system simplicityVSAvoidfailure detection capability

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

Ultrasonic waves serve as an intermediary between the loading process and failure detection. The transducers emit ultrasonic energy into the composite workpiece, and changes in the ultrasonic signal characteristics indicate the initiation of failure, providing a sensitive intermediate indicator that complements the load-displacement curve data.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances sensitivity, accuracy, and repeatability of measurement data, reduces labor and schedule costs, and ensures personnel safety by allowing continuous testing without manual intervention during mechanical loading.

Implementation Method 1

at least one ultrasonic testing transducer is mounted to a surface of a composite workpiece and configured to transmit and receive ultrasonic energy to and from the composite workpiece

Methodology Applied

Scientific EffectUltrasonic testing: Ultrasound

Data Source

PatentUS8185327B2Monitoring of composite materials

Publication Date: 2012.05.22 THE BOEING CO

AI summary

In a particular system for monitoring of a composite workpiece, at least one ultrasonic testing transducer is mounted to a surface of the composite workpiece and configured to transmit and receive ultrasonic energy to and from the composite workpiece during mechanical loading of the composite workpiece. An ultrasonic pulser/receiver is operatively coupled to the at least one ultrasonic testing transducer. A computing system is operatively coupled to the ultrasonic pulser/receiver. The computing system includes a data acquisition component configured to acquire data from the ultrasonic puller/receiver and a data analysis component configured to analyze the acquired data. The data analysis component may be further configured to analyze the acquired data for initiation of failure of the composite workpiece and/or growth of failure of the composite workpiece. Further, failure of the composite workpiece may include cracking and/or delaminating and/or disbonding.