X-Ray Diffraction Probe Inspection for Turbine Stress Mapping
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Solution Overview
Problem
Existing inspection systems for gas turbine engine components in aircraft propulsion systems are inadequate for efficiently identifying defects, strains, and stresses in components while minimizing downtime and costs.
Innovation Solution
An X-ray inspection system with a probe assembly and control assembly, featuring a probe head with an x-ray source and detectors, capable of scanning components to calculate strain and stress based on x-ray diffraction data, and identifying acceptable or unacceptable conditions by comparing to material thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional inspection systems are used for gas turbine engine components, then inspection can be performed, but inspection efficiency is low and aircraft downtime is excessive
Solution Approach 1:
The inspection system is divided into modular components including a probe assembly with integrated X-ray source and detectors, a flexible borescope guide tube for navigation, and a separate control assembly. This segmentation allows the system to be optimized for high-speed inspection while maintaining accessibility to engine components through the flexible guide tube mechanism.
Solution Approach 2:
The patent replaces traditional mechanical inspection methods with X-ray diffraction technology. The X-ray source generates beams that interact with engine components to produce diffraction patterns, which are captured by detectors and processed to identify defects, strains, and stresses. This substitution enables non-contact, high-speed inspection without requiring physical access or disassembly of engine components.
2Reliability
If comprehensive component inspection is performed, then defect identification improves, but inspection cost increases
Solution Approach 1:
The X-ray inspection system performs multiple inspection functions simultaneously using a single integrated probe assembly. The system can detect defects, measure strains, and calculate stresses in engine components all through the same X-ray diffraction mechanism. This multi-functionality eliminates the need for separate inspection systems and reduces overall inspection costs while maintaining comprehensive reliability.
Solution Approach 2:
The system uses parameter changes in the X-ray beam (such as wavelength, intensity, and angle) to optimize detection for different types of defects and material characteristics. By varying these parameters, the system can adapt to inspect different engine components and defect types without requiring multiple specialized systems, thereby reducing costs while maintaining high accuracy.
3Measurement precision
If X-ray diffraction inspection is performed, then strain and stress calculation is enabled, but device complexity increases
Solution Approach 1:
The patent merges the X-ray source, detectors, and control electronics into an integrated probe assembly that can be maneuvered through the flexible borescope guide tube. This consolidation reduces the overall system complexity by eliminating the need for separate, bulky components while maintaining the capability to perform precise strain and stress measurements through X-ray diffraction.
Solution Approach 2:
The flexible borescope guide tube acts as an intermediary that transmits the probe assembly from the external environment into the engine interior. This intermediary mechanism enables the complex X-ray inspection system to access confined engine spaces without requiring disassembly of the engine, thereby reducing operational complexity while maintaining measurement precision.
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
Facilitates efficient identification of defects and material characteristics with minimal aircraft downtime and cost, allowing for precise assessment of component integrity.
Implementation Method 1
The at least one x-ray source is configured to generate and direct a x-ray beam to a target material of a component
Implementation Method 2
Each of the first x-ray detector and the second x-ray detector is configured to receive an x-ray diffraction of the target material resulting from an interaction with the x-ray beam
Data Source
AI summary
An x-ray inspection system includes a probe assembly and a control assembly. The probe assembly includes a probe head including at least one x-ray source and a plurality of x-ray detectors. The at least one x-ray source is configured to generate and direct a x-ray beam to a target material of a component. The plurality of x-ray detectors includes at least a first x-ray detector and a second x-ray detector. Each of the first x-ray detector and the second x-ray detector is configured to receive an x-ray diffraction of the target material resulting from an interaction with the x-ray beam. The control assembly includes a controller configured to scan the component by controlling the at least one x-ray source to direct the x-ray beam to the target material and capturing material composition data for the target material from the x-ray diffraction received by the first x-ray detector and the second x-ray detector and calculate a strain or a stress of the target material based on the material composition data.