Ultrasonic Conformity Analysis of Aircraft Interposition Mastic
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Solution Overview
Problem
Current methods for verifying the conformity of faying-surface mastic in aircraft structures rely on visual inspection, which is unreliable and requires disassembly, leading to inefficiencies and potential errors.
Innovation Solution
A method utilizing an ultrasonic measuring unit to generate and measure ultrasonic signals through the structure, determining the thickness of the faying-surface mastic, and assessing conformity without disassembly, using a predetermined propagation model and auxiliary data like temperature and application time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection is used to verify mastic conformity, then the inspection method is simple and requires no special equipment, but the reliability is insufficient and disassembly is required
Solution Approach 1:
The patent replaces visual inspection (mechanical/optical system) with ultrasonic measurement (acoustic system). The ultrasonic measuring unit sends ultrasonic signals through the mastic layer and analyzes the reflected signals to determine thickness and conformity, providing reliable verification without requiring disassembly or complex visual access.
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary to indirectly measure the mastic properties. Instead of directly observing the mastic between superposed parts, the ultrasonic signal acts as a mediator that penetrates the structure and carries information about the mastic thickness and conformity back to the measurement system.
2Manufacturing precision
If disassembly, cleaning and reassembly protocol is implemented, then quality verification is thorough, but time consumption increases significantly
Solution Approach 1:
The patent performs quality verification of the mastic layer during the assembly process itself, before finalization. The ultrasonic measurement is conducted on the integrated structure without disassembly, allowing early detection of conformity issues and eliminating the need for time-consuming disassembly and reassembly protocols.
Solution Approach 2:
The patent enables the assembled structure to self-verify its own quality through ultrasonic measurement. The structure itself, with the mastic integrated between parts, can be measured directly without requiring taking it apart for inspection, thus the system serves its own verification needs.
3Measurement precision
If visual observation is used, then the inspection process is rapid, but detection precision is insufficient for internal defects
Solution Approach 1:
The patent replaces visual observation (optical system) with ultrasonic measurement (acoustic system). The ultrasonic waves can penetrate into the structure and interact with internal features like the mastic layer and any swarf, providing precise measurement of thickness and detection of defects that are invisible to visual inspection.
Solution Approach 2:
The patent transitions from two-dimensional visual surface inspection to three-dimensional internal measurement. Ultrasonic waves propagate through the volume of the mastic layer, allowing measurement of thickness and detection of internal defects throughout the entire volume, not just at the surface.
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 precise, rapid, and reliable verification of faying-surface mastic conformity and the detection of swarf without disassembling the structure, significantly reducing time and costs associated with aircraft assembly operations.
Implementation Method 1
a measuring step, implemented by an ultrasonic measuring unit, consisting in generating an ultrasonic signal, in sending the ultrasonic signal to the structure from at least one measurement point and in measuring the amplitude of the ultrasonic signal sent back by said structure as a function of a corresponding time-of-flight
Implementation Method 2
measuring the amplitude of the ultrasonic signal sent back by said structure as a function of a corresponding time-of-flight
Data Source
AI summary
A device (1) including an ultrasonic measuring unit (7) that sends an ultrasonic signal (S1) into a structure (2) and measures the amplitude of the ultrasonic signal (S2) reflected by the structure (2), a processing unit for determining the thickness of the interposition mastic (3) from the measurements of the ultrasonic measuring unit (7) and with the aid of a propagation model of the interposition mastic (3) which provides a thickness value of the interposition mastic (3) depending on the propagation time of the ultrasonic signal in the interposition mastic (3) as well as auxiliary data, and a processing unit for deducing a conformity or a lack of conformity of said interposition mastic (3) and the presence of cuttings from the thickness of the interposition mastic (3), the device (1) carrying out a conformity checking that is accurate, fast and reliable without having to disassemble the structure (2).