The Boeing Company

Jeffrey G Thompson

Gary E Georgeson

Morteza Safai

Tyler M Holmes

Barry Allen Fetzer

Clyde T Uyehara

John Ralph Hull

Jeffrey Reyner Kollgaard

Hong Hue Tat

Steven Kenneth Brady

William Joseph Tapia

Martin L Freet

Roger W Engelbart

Michael D Fogarty

David S Nansen

Jill Paisley Bingham

John F Spalding, Jr

Doris Kuhlmann-Wilsdorf

John Robert Linn

Carl B Gifford

Thomas E Riechers

Ronald E VonWahlde

David W Anderson

Andrew J McCulloch

Ronald V Bulthuis

John Bangsund

Gary Ernest Georgeson

A system and method for nondestructive inspection of a unitized composite structures is provided. The system includes an infrared thermographic camera and a carriage that can be mounted on, for example, adjacent frames of the unitized composite structure. The carriage can move along the length of the frames while the infrared thermographic camera collects and analyzes thermographic images of the frame, skin, and stiffeners. The carriage can be moved to other frames and the inspection continued until the entire unitized composite structure has be inspected.

Robotic infrared thermographic inspection for unitized composite structures

Methods for thermographic inspection of structures are disclosed. An example method includes positioning at least one of a heat source or a camera in a cavity defined by a first side of a structure of an aircraft and positioning the other one of the heat source or the camera at a second side of the structure opposite the first side; applying heat to the least one of the first side or the second side of the structure; measuring thermal energy emitted from the other one of the first side or the second side opposite the heat source; and identifying a defect or inclusion of the structure based on the measured thermal energy.

Methods for thermographic inspection of structures

An infrared (IR) thermography system for inspecting porosity of a test part of a given thickness is provided. The IR thermography system may include a thermal detector configured to detect IR signals emitted from the test part, and a controller in electrical communication with at least the thermal detector. The controller may be configured to at least determine thermal test data associated with the test part based on the IR signals, generate thermal model data based on the thickness of the test part, and determine porosity of the test part based on a comparison between the thermal test data and the thermal model data.

Infrared thermographic porosity quantification in composite structures

A system and method for the detection of foreign object debris materials or defects on and/or under a surface of a composite part under manufacture. A member, for example an inspection gantry, is configured to move over the surface. A thermal excitation source is fixed to the member and is configured to direct infrared radiation across the surface. An infrared camera is also fixed to the member a predetermined distance away from the thermal excitation source and is configured to scan the surface as the member moves over the surface to detect and output scan information of the surface. A controller is coupled to the excitation source and to the infrared camera. The controller is configured to process the scan information from the infrared camera to identify a foreign object debris material or defect located on and/or under the surface.

System and method for high speed surface and subsurface FOD and defect detection

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 system for the detection of foreign object debris material on a surface includes an ultraviolet light source configured to direct ultraviolet light across a surface. The surface is an outer surface of a composite part being formed by a composite layup machine. The system includes an ultraviolet light camera configured to scan the surface and output a first signal proportional to reflected ultraviolet light reflected by at least one of the surface and a first type of foreign object debris material. The reflected ultraviolet light is responsive to the ultraviolet light from the ultraviolet light source. The system also includes a controller coupled to the ultraviolet light source and to the ultraviolet light camera. The controller is configured to compare the first signal from the ultraviolet light camera with a first threshold to detect presence of the first type of foreign object debris material.

System and method for high speed FOD detection

A system for the detection of foreign object debris material on a surface of a composite part being manufactured. A platform is configured to move over the surface. A thermal excitation source is fixed to the platform and configured to direct infrared radiation across the surface. An infrared camera is also fixed to the platform and configured to scan the surface as the platform moves over the surface to detect and output a signal proportional to infrared radiation emitted by the surface and/or by any foreign object debris material on the surface in response to the infrared radiation from the excitation source. A controller is coupled to the excitation source and to the infrared camera and is configured to compare the signal from the infrared camera with a first predetermined threshold signal to detect if any foreign object debris material is located on the surface.

A system for nondestructive evaluation of a test object includes a platform, an electromagnetic acoustic transducer (EMAT) to create acoustic vibrations that travel along the test object; an infrared detector positioned to record thermal images of a plurality of test areas on the test object to detect flaws in the test object as the platform and the test object move relative to each other; and a control connected to actuate the EMAT and the infrared detector, synchronize the creation of vibrations with the recording of thermal images, receive a signal from the infrared detector indicative of the thermal image of the surface of the test object, and record locations of the flaws appearing on the thermal images of the test areas, all as the platform and the test object move relative to each other.

System and method for nondestructive evaluation of a test object

Method and apparatus for detecting defects in a composite is provided. After a ply of material for a workpiece is positioned, thermal energy is applied to a top surface of the ply of material, and a digital thermographic camera captures images of the top surface. A computer processor determines heat characteristics of the top surface to identify regions of the top surface with different heat characteristics. Such different areas are identified as regions that include a defect. The defect regions can be repaired prior to disposing additional plies of material over previously-applied plies.

In-process monitoring, automated decision-making, and process control for composite manufacturing using part-referenced ply-by-ply infrared thermography and other non-contact non-destructive inspection

A vehicle examination system includes an axle inspection system that is configured to inspect an axle of a vehicle. The axle inspection system includes an ultrasound scanning assembly, and an axle coupler that retains the ultrasound scanning assembly. The axle coupler is configured to moveably secure the ultrasound scanning assembly to the axle. An axle inspection control unit is in communication with the ultrasound scanning assembly. The axle inspection control unit is configured to control the ultrasound scanning assembly to ultrasonically scan the axle for anomalies as the vehicle moves.

Vehicle axle inspection systems and methods

Methods for identifying and quantifying wrinkles in a composite structure by processing infrared image data. The intensity and first and second time derivatives thereof at a particular time can be displayed as thermography line profiles on a graph in which the horizontal axis represents the pixel number across the field of view of an infrared camera. The spatial derivatives of the foregoing thermography line profiles can also be calculated and displayed as a graph. The maximum amplitude (i.e., height) of an out-of-plane wrinkle can be determined using a correlation/calibration curve that is constructed by correlating infrared image data with optical measurement data. In addition, the wavelength and maximum amplitude of an in-plane wrinkle can be measured directly from the thermography line profiles.

Characterization of wrinkles and periodic variations in material using infrared thermography

Method and apparatus for detecting defects in a laminate of uncured, compacted composite sheets. After a number of plies of composite sheets are arranged and compacted, a burst of heat energy is applied to a top surface of the laminate and a digital thermographic camera captures images of the top surface. A computer processor measures heat characteristics of the top surface to identify regions of the top surface with different heat characteristics. Such different areas are identified as regions that include a defect. The defect regions can be repaired by applying additional compaction and/or by removing at least a portion of some layers, removing any foreign object debris, replacing the layers, and compacting the replaced layers. After any defects are addressed, the laminate is cured.

Detecting inclusions and disbonds in green material repairs with thermography

A system and method for the detection of foreign object debris materials or defects on and/or under a surface (e.g., outer ply) of a composite part being formed by a composite layup machine. A gantry moves over the composite part along a predetermined length thereof. A thermal excitation source fixed to the gantry directs infrared radiation across the width of the surface of the composite part. A infrared camera fixed to the gantry a predetermined distance away from the thermal excitation source scans the surface as the gantry moves to detect and output scan information thereof. A controller is coupled to the thermal excitation source and to the infrared camera. The controller processes the sequence of infrared images to identify a foreign object debris material or defect located on and/or under the surface.

An optical scanning assembly for use in inspecting a channel is provided. The assembly includes a housing and an inspection probe that selectively advances from the housing along an axis. The probe includes a light source that directs light towards at least one side wall of the channel and a light detector that receives the light reflected from the side wall. The assembly further includes a controller in communication with the inspection probe. The controller obtains a first optical length measurement for the light reflected from the side wall when the inspection probe is in a first position along the axis within the channel, obtain a second optical length measurement for the light reflected from the side wall when the inspection probe is in a second position along the axis within the channel, and compare the first and second optical length measurements to determine variations in a geometry of the channel.

Optical scanning assembly and method of inspecting a channel

A method for determining an actual shear angle between an interior wall and a facesheet of a cellular panel using an imaging system is disclosed. The imaging system may include a radiation source and a detector diametrically opposed to the radiation source. The method may include positioning the cellular panel at a tilt angle relative to a line extending between the radiation source and the detector, transmitting radiation from the radiation source to the detector through the cellular panel at the tilt angle to obtain an image, measuring a projected shear angle in the obtained image, and determining the actual shear angle between the interior wall and the facesheet using the tilt angle and the projected shear angle.

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Auburn, WA, United States of America

Jeffrey G Thompson