Void-Defect Coupon Standards for NDT Sensitivity

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Solution Overview

Problem

Existing non-destructive testing methodologies are limited in their ability to detect certain types and sizes of defects, and their sensitivity can be impacted by the size, shape, and material of the manufactured component.

Innovation Solution

The development of standards for non-destructive testing methodologies that include void-defect coupons with specific geometric features, such as spheroidal and elongated voids, to assess and quantify the sensitivity of testing methods to defects of varying sizes and shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If non-destructive testing methodologies are used to inspect manufactured components, then defect detection capability is improved, but the ability to detect all types and sizes of defects is limited due to sensitivity constraints

Engineering Contradiction:

Improvedefect detection sensitivityVSAvoiddetection coverage across defect types

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by creating void defects with specific dimensional parameters (spheroidal voids with 0.5-2.0 mm diameters, elongated voids with specific length-to-diameter ratios) to systematically evaluate how different defect parameters affect NDT methodology sensitivity. This allows quantification of detection capabilities across varying defect sizes and shapes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements local quality by introducing voids with different local geometries (spheroidal vs. elongated shapes) at specific locations within coupons to assess how local defect characteristics influence detection sensitivity. This enables targeted evaluation of NDT methods for specific defect morphologies

Inventive Principle:

Principle #3Local quality

2Measurement precision

If standards with multiple void types are created to evaluate NDT sensitivity, then defect detection accuracy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesensitivity quantification accuracyVSAvoidcoupon manufacturing complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-establishing standardized void-defect coupons with known defect characteristics before NDT methodology evaluation. These coupons serve as reference standards that enable systematic and repeatable sensitivity measurements without requiring complex real-time defect creation during testing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements segmentation by dividing the evaluation system into standardized coupon units, each containing specific void configurations. This modular approach allows systematic testing of different void types while maintaining manufacturing consistency and simplifying the overall evaluation process

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12253477B2Standards for non-destructive testing methodologies and methods of fabricating the standards

Publication Date: 2025.03.18 THE BOEING CO

AI summary

Standards for non-destructive testing methodologies and methods of fabricating the standards are disclosed herein. The standards include a void-defect coupon that includes a spheroidal void and an elongated void. The spheroidal void has a maximum dimension and a spheroidal void volume. The elongated void had a longitudinal dimension, a maximum transverse dimension, and an elongated void volume. The longitudinal dimension of the elongated void is greater than the maximum dimension of the spheroidal void. The maximum transverse dimension of the elongated void is less than the maximum dimension of the spheroidal void. The methods include forming a first void-defect coupon and forming a second void-defect coupon.