Ultrasonic Inspection of Composite Parts Using Surface Shape Adaptation
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Solution Overview
Problem
Current methods for inspecting large-scale monolithic composite aircraft structures with internal cavities, such as soft tooling and synthetic aperture ultrasonic imaging, are inefficient and fail to detect minor defects due to the complexity and fragility of mechanical devices and the lack of refinement in non-destructive inspection images.
Innovation Solution
A method and system for ultrasonic inspection that uses an initial ultrasonic pulse to determine the shape of a part's surface, followed by a surface inspection signal and potentially a full part inspection signal, transmitted via an array of antenna elements to detect defects with higher resolution, utilizing echo travel time and signal magnitude to refine the inspection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If synthetic aperture ultrasonic imaging is used to inspect surface shape, then inspection coverage is improved, but image refinement and defect detectability deteriorate
Solution Approach 1:
The system performs preliminary surface shape determination using an initial ultrasonic signal before conducting the actual defect inspection. This preliminary action allows the system to adapt the inspection signal parameters (beam width, focal depth, steering angle) based on the actual surface geometry, thereby improving defect detectability while maintaining comprehensive coverage
Solution Approach 2:
The system dynamically changes ultrasonic signal parameters including beam width, focal depth, and steering angle based on the determined surface shape. This parameter adaptation enables the inspection system to optimize resolution for detecting minor defects while maintaining broad inspection coverage across complex geometries
2Measurement precision
If small oscillating mechanical fixtures are used to inspect surface shape, then surface shape measurement is improved, but device complexity and maintenance requirements worsen
Solution Approach 1:
The system replaces complex mechanical oscillating fixtures with an ultrasonic-based surface shape determination method. By using ultrasonic signals to probe surface geometry and determine shape characteristics, the system eliminates fragile mechanical components while maintaining measurement capability, thereby reducing device complexity and maintenance requirements
Solution Approach 2:
The ultrasonic inspection system performs self-characterization by using its own transmitted signals to determine surface shape and geometry. The system analyzes the reflected ultrasonic signals to automatically adapt inspection parameters without requiring external mechanical measurement devices, simplifying the overall inspection apparatus
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 enables more accurate and efficient detection of surface and subsurface defects in composite materials, improving defect detectability and reducing production downtime and maintenance costs by using conventional ultrasonic array interrogation beams and processing algorithms.
Implementation Method 1
reflecting, off of a surface of the part, at least a portion of the initial signal to generate a surface reflection signal
Data Source
AI summary
Systems, methods, and apparatus for ultrasonic inspection of parts are disclosed. A method for inspection of a part comprises transmitting, by a source, an initial signal towards the part. The method further comprises reflecting, off of a surface of the part, the initial signal to generate a surface reflection signal. Also, the method comprises receiving, by a receiver, the surface reflection signal. In addition, the method comprises determining, by a processor(s), a shape of the surface of the part by using a magnitude of the surface reflection signal and an echo travel time of the initial signal with respect to the surface reflection signal. Additionally, the method comprises determining, by a processor(s), a surface inspection signal commensurate with the shape of the surface of the part. Further, the method comprises transmitting, by the source, the surface inspection signal towards the part for inspection of the surface of the part.