The Boeing Company

Fred D Young

Barry Allen Fetzer

Hien T Bui

Mark A Lee

Troy W Brunty

James C Kennedy

Clyde T Uyehara

Michael J Duncan

Richard C Krotzer

James E Cook

Joseph Curtis Taylor

Dennis P Sarr

Martin L Freet

Justin D Serrill

Thomas E Riechers

Kate Brown Boudreau

Edward L Puckett

Kevin R Bray

Kate Summers

William M Lankelis

Systems and methods are provided for ultrasonic inspection. One embodiment is a method for ultrasonic inspection. The method includes selecting an ultrasonic probe having an array of transducers arranged in an arc, placing the ultrasonic probe atop a surface of a part having a first radius of curvature, dynamically aligning the transducers of the array with respect to the surface, forming an ultrasonically conductive pathway between the transducers and the part, and inspecting the part via ultrasonic waves transmitted from the transducers.

Ultrasonic cap radius probe providing constant fluid path length

In accordance with one or more aspects of the present disclosure, an apparatus for inspecting a part having a non-linear cross section includes a stationary sensor element including at least one phased array sensing unit, each of the at least one phased array sensing unit having a shape that is geometrically complimentary to the non-linear cross section of the part, and a support for the part having the non-linear cross section, the support comprising a drive assembly configured to move the part relative to the stationary sensor element, through an inspection beam emitted from the at least one phased array sensing unit.

Method and apparatus for inspecting a part having a non-linear cross-section

An ultrasound scanning assembly is configured to inspect a structure, such as a composite winglet of an aircraft. The ultrasound scanning assembly may include an outer ultrasound probe configured to be positioned on an outer surface of the structure. The outer ultrasound probe may include a phased array transducer having a plurality of transducer elements. An inner ultrasound probe may be configured to be positioned within the structure opposite from the outer surface. The inner ultrasound probe may include a single element transducer configured to receive ultrasound signals transmitted by the phased array transducer.

Ultrasound scanning system, assembly, and method for inspecting composite structures

An ultrasonic probe includes a probe body having a contact surface and a cavity that is open at the contact surface, an ultrasonic transducer carried by the body, and a spacer within the cavity. The spacer has a first surface acoustically coupled to the transducer, and a second (coupling) surface within the cavity. The spacer propagates an acoustic signal between the transducer and the coupling surface. The coupling surface is spaced apart from the contact surface to form a recess within the body. The body further has at least one port for circulating a coupling fluid into the recess. Depth of the recess is selected to balance gravitational force on the coupling fluid versus surface tension of the coupling fluid so a bead of the fluid forms over an edge of a structure under inspection as the probe is moved over the edge.

Ultrasonic probe

An ultrasonic probe performs non-destructive inspection of a corner radius of a part. According to one embodiment, an ultrasonic probe includes an ultrasonic sensor array, and a shoe for holding the sensor array and moving the sensor array along the radius of the part. The shoe includes means for adjusting the sensor array so all ultrasonic beams from the sensor array have the same water path distance to a center of the radius, and for adjusting the sensor array so that all beams pass through the center of the radius.

Ultrasonic testing of corner radii having different angles and sizes

A part holder for immersion ultrasonic testing having a solid buffer material with acoustic properties that match the immersion fluid is disclosed. Test systems and methods are also disclosed.

Immersion ultrasonic test part holder, system and method for nondestructive evaluation

Apparatus, systems, and methods for inspecting a structure are provided which permit inspection of uniquely shaped structures such as fuselage frames and shear ties. Probes may be constructed from rapid prototyping. Inspection may be performed manually and may use a portable function support system for delivering fluid couplant, controlling transmit and receive functions of the inspection sensors, and delivering immediate visual analysis for an operator. Integrated ultrasonic inspection apparatus, systems, and methods facilitate fast and efficient custom inspection devices and inspecting otherwise difficult-to-inspect structures.

Integrated ultrasonic inspection probes, systems, and methods for inspection of composite assemblies

An ultrasonic probe for examining an item. The probe includes a body having a contact surface adapted for contacting the item when being examined and an ultrasonic transducer attached to the body and spaced from the contact surface. The probe further includes a spacer positioned in the body between the transducer and the contact surface for spacing the transducer from the item when being examined. The spacer includes a coupling surface facing the item when being examined and a transducer surface facing the transducer. The probe also includes a fluid outlet positioned adjacent the coupling surface of the spacer for delivering coupling fluid to the coupling surface as a film so that the coupling fluid tends to maintain contact with the spacer due to surface tension after the fluid is delivered through the outlet.

Thin-film ultrasonic probe

An apparatus including a linear array transducer coupled to an upper housing of the apparatus and positioned above a tapered chamber. The tapered chamber configured to maintain a column of couplant between the linear array transducer and a structure to be inspected as the linear array transducer is positioned over an edge of the structure.

Probe for inspection of edges of a structure

A system and method for inspecting a structure are provided. The system includes at least one non-destructive inspection ('NDI') sensor capable of acquiring data indicative of at least a portion of the structure, and at least one positional sensor for acquiring positional data of the NDI sensor. The system also includes a mechanism operable to trigger the NDI sensor and/or the positional sensor to acquire data such that data indicative of the structure and the positional data are acquired at approximately the same time. The system further includes a movable arm carrying the sensors and movably attached to a base. The system includes a data acquisition system capable of communicating with the sensors such that the data acquisition system generates information indicative of at least a portion of the structure based on the data acquired by the sensors.

Inspection system and associated method

An apparatus for the ultrasonic testing of internal areas of prefabricated composite assemblies as described. The composite assemblies have one or more internal areas formed therein. The apparatus includes at least one receive transducer, at least one transmit transducer, a vertical member, a support member slidably attached to the vertical member, a pair of substantially parallel hollow rods, and an ultrasonic testing system. Each rod comprises a transducer attachment end with receive transducers attached to the transducer attachment end of a first rod, and transmit transducers attached to the transducer attachment end of a second rod. The rods are slidably attached to the support member and manually movable with respect to a composite assembly to be tested. The ultrasonic testing system is coupled to the receive transducers through the first rod, and coupled to the transmit transducers through the second rod.

Methods and systems for inspection of composite assemblies

An ultrasonic one pass inspection system for determining the presence, location, and size of flaws in laminated structure such as an &ldquo;I&rdquo; stiffener in a single inspection cycle. The exemplary system includes an immersion tank, six (6) single probes, 184 transducers, four (4) motor assemblies, two (2) encoder assemblies, a collection tank, and a recirculation assembly. The probes are designed to match the shape of the stiffener. Two (2) motors fore and two (2) motors aft of the immersion tank, produce information related to the position of the stiffener with respect to the position of the transducer. The position encoder is spring-loaded against the stiffener.

Ultrasonic inspection system for laminated stiffeners

An ultrasonic one pass inspection system for determining the presence, location, and size of flaws in laminated structure such as an 'I' stiffener in a single inspection cycle. The exemplary system includes an immersion tank, six (6) single probes, 184 transducers, four (4) motor assemblies, two (2) encoder assemblies, a collection tank, and a recirculation assembly. The probes are designed to match the shape of the stiffener. Two (2) motors fore and two (2) motors aft of the immersion tank, produce information related to the position of the stiffener with respect to the position of the transducer. The position encoder is spring-loaded against the stiffener.

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Bellevue, WA, United States of America

Fred D Young