Ultrasonic Mesh Detection for Orientation-Independent Aircraft Defects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods such as radiography and ultrasonic measurements are inadequate for detecting defects like porosities and lack of fusion in parts manufactured by Direct Energy Deposition (DED) methods, particularly in aircraft components, especially when these defects have varied shapes and orientations.
Innovation Solution
An ultrasonic detection method using a meshed arrangement of emitters and receivers, combined with data processing to calculate global amplitudes and detect defects across different orientations, and a system comprising ultrasonic transmitters and receivers to perform measurements on a divided area of interest.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If standard radiography and ultrasonic measurements are used, then detection capability for rounded defects is achieved, but detection capability for linear defects with various orientations is insufficient
Solution Approach 1:
The area of interest is divided into a mesh of elementary cells, and the ultrasonic measuring device is divided into multiple emitters and receivers. Each emitter-receiver pair measures a specific cell, enabling comprehensive coverage of the inspection area from multiple angles to detect defects of various orientations and shapes.
Solution Approach 2:
The patent transitions from conventional single-angle ultrasonic measurement to multi-angle measurement by arranging multiple emitters and receivers in space. This spatial dimensionality enhancement allows ultrasonic waves to probe the part from different directions, making it possible to detect linear defects regardless of their orientation.
2Measurement precision
If multiple emitters and receivers are used to measure each cell from different angles, then detection capability for all defect types is improved, but measurement time and processing complexity increase
Solution Approach 1:
The area of interest is pre-divided into a mesh of elementary cells before inspection begins. This preliminary segmentation allows the inspection system to systematically target each cell with specific emitter-receiver pairs, optimizing the measurement sequence and reducing redundant measurements while ensuring complete coverage.
Solution Approach 2:
The patent varies the measurement parameters by using different emitter-receiver pairs for different cells, changing the ultrasonic wave paths and measurement angles. This parameter variation enables detection of defects with different orientations and shapes, improving overall detection accuracy without requiring exhaustive measurement of all possible angles for each cell.
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
The method and system effectively detect all defects in parts, including linear and rounded ones, regardless of their orientation, providing precise and reliable conformity checks during manufacturing and maintenance.
Implementation Method 1
the generation by the ultrasonic emitter in question of an ultrasonic signal which is sent into the part and the measurement, by each of the ultrasonic receivers of the ultrasonic measuring device, of the amplitude of the corresponding ultrasonic signal, returned by the cell considered in the part
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
- Method and system for ultrasonic detection of internal defects in a part, particularly for an aircraft.- The system (1) includes an ultrasonic measuring device (4) comprising a plurality of ultrasonic emitters and ultrasonic receivers, the ultrasonic measuring device (4) performing ultrasonic measurements on an area of interest of the part divided according to a mesh comprising cells, and performing the measurements cell by cell with the generation by each ultrasonic emitter of an ultrasonic signal sent into the part and the measurement, by each of the ultrasonic receivers, of the amplitude of the ultrasonic signal returned by the cell considered of the part, an element (7) to calculate, for each of the cells of the mesh, the sum of the amplitudes of all the measurements performed for that cell and a processing element (9) to deduce the presence or not of one or more defects, the system (1) thus making it possible to detect all the defects existing in the area of interest of the part, whatever their orientation.