The Boeing Company

Theboeing Company

Hong Hue Tat

Yuan-Jye Wu

Gary E Georgeson

Richard Henry Bossi

Tyler M Holmes

John Z Lin

Barry Allen Fetzer

Jeffrey G Thompson

William Joseph Tapia

Joseph D Schaefer

Brian T Miller

Jason Wu

Russell Lee Keller

Robert Alan Smith

David Keith Mefford

Martin L Freet

Anne Kao

Grant C Zenkner

Mary J Mathews

Kelly M Greene

Michael J Schaffer

Carlyn R Brewer

Kerth J Downs

Wayne A Berry

Victor P Pauca

Rongzhong Li

Christina I Fraij

Mark Daniel Winters

James C Kennedy

Brice Aaron Johnson

Alan Frank Stewart

Michael D Fogarty

Mostafa Rassaian

John A Mittleider

Sayata Ghose

Jill Paisley Bingham

Panagiotis Emanuel George

Benjamin Emerson Carl Koltenbah

Christopher R Loesche

Vladimir Balabanov

Robert L Carlsen

Ashley C Tracey

Edward L Puckett

Olaf Weckner

Sadie Lee Fieni

Thomas A Maeder

Scott Hutchinson Gardner

Kari P Larkin

Vicki Wu

John-Paul Nathaniel Sabino

John M Pryor

Bharath Kumar Kodumuru

Clayton M Little

Chelsey Elizibeth Henry

Jeremy Robert Larkin

Matthew G Pike

James W Edwards

Anuj K Adhikaram

Edward J Kang

Kathryn T Moore

Nathan J Chapdelaine

Baljinder Singh

Gary Ernest Georgeson

Scott H Gardner

John-Paul N Sabino

Mary J Matthews

Methods and scan systems for analyzing an object. The methods include obtaining a local operation dataset that includes a plurality of operation data points obtained from an object and a corresponding location, within the operation coordinate system, for each operation data point of the plurality of operation data points. The methods also include mapping the plurality of operation data points from the operation coordinate system to a global coordinate system for the object. The mapping includes mapping to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system, for each operation data point. The scan systems include a robot that performs a plurality of operations on an object within an operation coordinate system and a computing device that maps the plurality of operation data points from the operation coordinate system to a global coordinate system.

Methods and scan systems for analyzing an object

A method for quantitatively evaluating the expected ultrasonic inspectability of a designed part using ray tracing. First, a model of a part imported. Materials having different indices of refraction are selected for the part and an acoustic coupling medium. Then the following structures and positional relationships are defined: an ultrasonic transducer array comprising a plurality of elements, a position of the acoustic coupling medium between the transducer array and the part, and a plurality of positions of a transmit aperture relative to the part. For each defined position of the transmit aperture, a path of a respective ray is traced from a center of the transmit aperture through the part and then to a respective receive location on the transducer array. Also, a respective value of an inspectability margin is calculated based at least in part on a respective distance between a center of the receive aperture and the respective receive location. Each value of the inspectability margin is compared to a threshold value.

Ultrasonic inspection margin check for design and manufacturing

An example system includes two objects each having a known dimension and positioned spaced apart by a known distance, and a fixture having an opening for receiving an imaging device and for holding the two objects in a field of view of the imaging device such that the field of view of the imaging device originates from a point normal to a surface of the base. The fixture holds the imaging device at a fixed distance from an object being imaged and controls an amount of incident light on the imaging device. An example method of determining image scaling includes holding an imaging device at a fixed distance from an object being imaged, and positioning the two objects in the field of view of the imaging device such that the field of view of the imaging device originates from a point normal to a line formed by the known distance.

Systems and methods of determining image scaling

Methods that provide wrinkle characterization and performance prediction for wrinkled composite structures using automated structural analysis. In accordance with some embodiments, the method combines the use of B-scan ultrasound data, automated optical measurement of wrinkles and geometry of cross-sections, and finite element analysis of wrinkled composite structure to provide the ability to assess the actual significance of a detected wrinkle relative to the intended performance of the structure. The disclosed method uses an ultrasonic inspection system that has been calibrated by correlating ultrasonic B-scan data acquired from reference standards with measurements of optical cross sections (e.g., micrographs) of those reference standards.

Wrinkle characterization and performance prediction for composite structures

A manufacturing system includes a printhead, at least one profilometer, and a control system. The printhead extrudes a material onto a substrate and forms a new bead during additive manufacturing of an in-work article. The profilometer moves with the printhead and measures an in-work cross-sectional profile of existing beads of the in-work article. The control system generates in-work profile data including the in-work cross-sectional profile at a plurality of in-work profile locations, and continuously compares the in-work profile data to reference profile data of a reference article. The reference profile data includes a reference cross-sectional profile at a plurality of reference profile locations. The control system adjusts, based on the profile comparison, one or more bead forming parameters and causes the printhead to form the new bead according to the bead forming parameters to reduce or prevent nonconformities associated with forming the new bead.

Bead-type additive manufacturing system and method

An example fixture includes a hollow elongate section having a first end and a second end, and the first end has an opening for receiving a lens portion of an imaging device and the second end is structurally configured to brace against a surface of an object being imaged. The hollow elongate section is configured to hold the lens portion of the imaging device at a fixed distance from an object being imaged and to control an amount of incident light on the lens portion. Example methods of configuring an imaging device for capturing images of an object include holding, via a fixture, a lens portion of an imaging device at a fixed distance from an object being imaged, controlling an amount of incident light on the lens portion of the imaging device, and holding a calibration object in a field of view of the imaging device.

Fixtures, systems, and methods for configuring an imaging device for capturing images of an object

An example system includes a base, two objects each having a known dimension and positioned on the base spaced apart by a known distance, an imaging device positioned such that the two objects are in a field of view of the imaging device and such that the field of view of the imaging device originates from a point normal to a surface of the base, and a computing device having one or more processors and non-transitory computer readable medium storing instructions executable by the one or more processors to perform functions. The functions include receiving an image from the imaging device capturing the two objects in the field of view, and based on one or more of the known dimension of the two objects and the known distance between the two objects, determining an image scaling factor that associates a number of pixels in the image to a physical distance.

An infrared camera is directed aft of a compaction roller of a composite laying head. Heat is applied to a substrate by a heater mounted forward of the compaction roller. Infrared images are captured of composite tows laid down on a substrate by the compaction roller. Whether the composite tows have sufficient contact is determined using the infrared images.

Method and apparatus for controlling contact of composite tows

A method of detecting a compound in a material sample is presented. A transformation is generated from a set of IR spectra of a set of identified compounds, in which the compound is one of the set of identified compounds. The transformation is applied to an IR spectrum of the material sample to form a transformed IR spectrum. A decomposition is applied to the transformation. Results indicative of a presence or an absence of the compound are generated based on an output of the decomposition.

Detection of compounds in material samples utilizing a transformation and subsequent decomposition

A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Analysis of a structure modeled with inconsistencies mapped thereon

A system and method combine ablation of a surface of a part with inspection of the internal integrity of the part. A laser may direct an ablative laser pulse at the surface of the part sufficient to remove a portion of material from the part surface and to cause the part to produce an ultrasound waveform. A positioning system may provide relative movement of the ablative laser pulse and the part for application of a series of ablative laser pulses at a series of locations over an area of the surface of the part. An ultrasonic detection device may couple to the part to receive the ultrasound waveform and transmit it to a part inspection system that has stored a set of reference waveforms in a control computer. The system compares the ultrasound waveform to one or more of the reference waveforms to detect and characterize anomalies in the part.

System combining laser ablation with ultrasound inspection of parts

Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Thermography inspection for near-surface inconsistencies of composite structures

A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.

Ultrasonic inspection of a structure with a ramp

An apparatus comprises an acoustic sensing system and an analyzer module. The acoustic sensing system is positioned relative to an object, wherein the acoustic sensing system detects acoustic emissions and generates acoustic waveform data for the acoustic emissions detected. The analyzer module is implemented in a computer system that receives load data and the acoustic waveform data for the object, generates a plurality of frequency distribution functions using the acoustic waveform data, and generates a frequency distribution function time evolution image containing a plurality of points of each of the plurality of frequency distribution functions.

Method and apparatus for acoustic emissions testing

In an example, a method for forming a composite part includes, based on a part specification, cutting layers of material in a sequence and positioning the layers to form a stack. For each layer, after positioning the layer and before cutting a next layer in the sequence, the method includes (i) scanning along a length of the layer to determine an image, (ii) determining, based on the image, at least two edges of the layer, (iii) determining, based on the edges, a measured width at locations along the length of the layer, (iv) comparing the measured width at each location to a target width at the location, (v) deciding, based on the comparison, whether to adjust the production process, and (vi) if the decision is to adjust the production process, then adjusting the production process based on the comparison. The part specification specifies the target width at each location.

Systems and methods for forming a composite part based on volume

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Redmond, WA, United States of America

Hong Hue Tat