The Boeing Company

April L Beisiegel

Christopher Mark Vaccaro

Roger W Engelbart

David A Lilienthal

Ron DeFonce

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate, such as a metallic interleaved composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness, at least one metallic shim, and at least one mesh. A plurality of metallic shims and meshes may be disposed in alternating layers within the member. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the metallic shim may aide in modeling a metallic laminate. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards, such as porous metallic interleaved composite laminate reference standards, in the aircraft industry and in other non-aircraft applications.

Pseudo porosity reference standard for metallic interleaved composite laminates

The invention relates to tapered reference standards, and methods for their manufacture and use. An ultrasonic inspection reference standard for tapered, composite materials may include a member having at least one tapered section. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The tapered reference standards may substantially mimic the affect on ultrasonic sound passing through tapered sections in composite laminates.

Tapered ultrasonic reference standard

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh produces a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing a mesh

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness. The member may be defined by at least one hollow, non-spherical shaft. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The non-spherical shaft may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing one or more hollow, non-cylindrical shafts

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a cored composite laminate having porosity. An ultrasonic inspection reference standard for cored composite laminates having porosity may include a member having at least one thickness, at least one core, and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the core may aide in modeling a cored composite laminate. The manufactured reference standard may replace more costly porous, cored, composite laminate reference standards in the aircraft industry and in other non-aircraft applications.

Pseudo porosity reference standard for cored composite laminates

The disclosure relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one discrete wire. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The discrete wire may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing one or more discrete wires

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one discrete wire. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The discrete wire may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

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Freeburg, IL, United States of America

April L Beisiegel