The Boeing Company

David A Lilienthal

Christopher Mark Vaccaro

April L Beisiegel

Gary E Georgeson

Joseph Lawrence Hafenrichter

James C Kennedy

William Paul Motzer

Mark A Ulvin

Eileen E Miller

Sadie Lee Fieni

Ronald Leroy McGhee

Walter Jefferson Harris

Kristofer Logan Peterson

Eddie Thelonious Boyd

Kristofer L Peterson

Ronald Leroy Mcghee

Mark Allen Ulvin

Non-destructive test systems and associated methods. A non-destructive test system includes an infrared thermography assembly and an ultrasonic test assembly for testing a test piece. The infrared thermography assembly may include one or more thermography sensor modules and a thermography test controller. The ultrasonic test assembly may include one or more ultrasonic sensor subassemblies with respective excitation modules and respective detector modules and an ultrasonic test controller. Each excitation module may be configured to produce a respective ultrasonic beam within the test piece, and each detector module may be configured to detect a respective reflected vibration of the test piece. In some examples, a method of performing a non-destructive test on a test piece includes testing an infrared test region of the test piece with an infrared thermography assembly and testing an ultrasonic test region of the test piece with an ultrasonic test assembly.

Non-destructive test systems with infrared thermography assemblies and ultrasonic test assemblies, and associated methods

A method for fabricating a composite structure is provided. A first number of layers of composite material is laid up to form a first set of stiffeners. A second number of layers of composite material is laid up to form a panel. The first set of stiffeners is associated with a first side of the panel. A pre-cured composite strip is positioned on a second side of the panel, opposite the first side. A third number of layers of composite material is laid up on the second side of the panel to form a second set of stiffeners running perpendicular to the first set of stiffeners. The pre-cured composite lies at an intersection between one of the first set of stiffeners and one of the second set of stiffeners. All the layers of composite material are co-cured to form the composite structure.

Method for co-curing perpendicular stiffeners

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

Ultrasonic measurements of porosity in manufactured parts or materials are calibrated using reference standards in which parallel holes are drilled in the backside of a body of material. The holes simulate voids in a part which attenuate incident ultrasonic energy. The number, size and location of the holes determine the simulated level of porosity that may be used to calibrate an ultrasonic tester. Multiple reference standards representing different levels of porosity can be produced in the form of individual coupons, or in a single body having multiple groups of holes.

Reference standard for ultrasonic measurement of porosity and related method

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

An ultrasonic inspection reference standard for composite materials having porosity may include a member, having at least one thickness and defined by a plurality of holes, that is manufactured from a fiber-free polymer resin. The ultrasonic inspection reference standard may have similar acoustic properties to prior art, porous, fiber-reinforced, composite reference standards, at lower manufacturing cost. A photo-polymer resin reference standard, having at least one thickness and defined by a plurality of holes, may be created using a stereo lithography process. The polymer resin reference standard may replace more costly porous, fiber-reinforced, composite reference standards. The ultrasonic inspection reference standard, manufactured from a polymer resin, may be used for ultrasonic inspection of porous, fiber-reinforced composite parts in the aircraft industry and in other non-aircraft applications.

Ultrasonic inspection reference standard for porous composite materials

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.

An ultrasonic inspection reference standard for composite materials includes a prism that is manufactured from a polymer resin. The ultrasonic inspection reference standard may be a rectangular prism and may be a polymer resin step-wedge reference standard that has similar acoustic properties as prior art fiber-reinforced composite step-wedge reference standards at significantly lower manufacturing cost. A photo-polymer resin reference standard may be created using a stereo lithography process. The polymer resin reference standard may replace a currently used expensive fiber-reinforced composite reference standard. The ultrasonic inspection reference standard manufactured from a polymer resin may be used, for example, for ultrasonic inspection of fiber-reinforced composite parts. The polymer resin reference standard may be used, for example, in the aircraft airframe industry, both commercial and defense.

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Kent, WA, United States of America

David A Lilienthal