Ultrasonic Waveform Mapping for Weak Bond Boundaries
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Solution Overview
Problem
Conventional non-destructive testing techniques face difficulties in reliably identifying the boundary between sound and weak bonds in multilayer articles, which can lead to safety issues and increased maintenance costs due to potential catastrophic failures.
Innovation Solution
A method and system utilizing ultrasonic waves to generate full-wave, time domain waveforms at multiple positions on a multilayer article, comparing waveform characteristics to determine bond boundaries between sound and weak bonds, and marking or memorializing these positions for further analysis or repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional non-destructive testing techniques are used, then bond failure areas can be identified, but weak bond areas cannot be reliably detected
Solution Approach 1:
The patent changes the measurement parameters from conventional ultrasonic testing to full-wave time domain waveform analysis. By capturing and analyzing the complete waveforms including amplitude, time of flight, and wave shape characteristics, the system can detect subtle variations that indicate weak bonds rather than just complete bond failures. This parameter transformation enables reliable identification of both sound and weak bond regions.
Solution Approach 2:
The patent replaces conventional mechanical or simple ultrasonic testing methods with an advanced waveform analysis system. The system uses full-wave time domain waveform capture and comparison algorithms to substitute traditional detection mechanisms, enabling more precise differentiation between sound and weak bonds through computational analysis of ultrasonic wave characteristics.
2Reliability
If conventional ultrasonic testing is performed, then bond quality can be assessed, but accurate boundary identification between sound and weak bonds is difficult
Solution Approach 1:
The patent segments the bond region into distinct zones (sound bond, weak bond, and transition zones) by comparing waveforms at multiple positions. By dividing the assessment into discrete location comparisons and identifying waveform characteristic changes between adjacent positions, the system can precisely locate boundaries between different bond quality regions rather than providing a general assessment.
Solution Approach 2:
The system uses waveform comparison feedback between adjacent positions to iteratively identify boundary locations. By continuously comparing waveforms and detecting changes in waveform characteristics, the system provides feedback that enables precise boundary identification through systematic position-by-position analysis.
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 accurate identification and differentiation of bond boundaries, allowing for targeted repair or removal of weak bond regions, thereby enhancing the safety and utility of multilayer articles by improving the reliability of bond quality assessment.
Implementation Method 1
obtaining a full-wave, time domain waveform of ultrasonic waves reflected from the article
Data Source
AI summary
A method of identifying a bond boundary between a sound bond and weak bond in a multilayer article may include determining a plurality of positions on a surface of the article; for each position of the plurality of positions, obtaining a full-wave, time domain waveform of ultrasonic waves reflected from the article; and, for each pair of adjacent positions among the plurality of positions, determining whether there is a bond boundary between a first position and a second position based on a comparison of a waveform characteristic of a first waveform generated at the first position and the waveform characteristic of a second waveform generated at the second position; and in response to a determination that there is a bond boundary between the first position and the second position, determining a boundary position based on the first position and the second position and memorializing the boundary position.