Edison Welding Institute, Inc.

Cumberland & Western Resources, LLC

United States of America As Represented by the Secretary of the Air Force

Kbr Wyle Services, LLC

Jeong K Na

Paul Boulware

Roger L Spencer

Sean T Gleeson

Scott A Newhouse

James L Blackshire

Erin K Oneida

Bill Colgan

Shaun L Freed

Ron Brown

Paul C Boulware

Roger Spencer

An apparatus for non-destructive ultrasonic testing is disclosed that permits focused immersion measurements to be accomplished in a non-immersion, contact mode. The apparatus includes an adaptor for acoustically coupling an elastomeric body to a focused ultrasonic transducer via an acoustic couplant. The adaptor includes a housing for receiving the elastomeric body on one end, and the ultrasonic transducer on another end. A cavity is defined within the housing for receiving a liquid medium that acoustically couples the ultrasonic transducer to the elastomeric body. The elastomeric body has a frontal surface disposed at a face slant angle relative to a longitudinal axis, where the face slant angle can be optimized for the test material. The volume of the housing cavity may be adjusted so as to vary the focal length of the ultrasonic transducer.

Elastomer ultrasonic coupling adaptor for focused transducers

A system and methods of nondestructive testing are described. The system includes an immersion ultrasonic probe and a laser vibrometer. The immersion ultrasonic probe and a sample are immersed in a fluid contained in an immersion tank and the laser vibrometer is disposed outside of the immersion tank. A tightly focused ultrasonic beam from the immersion ultrasonic probe and a laser beam from the laser vibrometer are both transmitted upon a sample, the laser beam being transmitted through the wall of the immersion tank. Since the ultrasonic beam is tightly focused and the laser beam samples only a small area impinged by the ultrasonic beam, microscopic resolution is obtained.

Micro-resolution ultrasonic nondestructive imaging method

A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that includes software having at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of a characterized laser weld.

Phased array system for inspection of laser welds

A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.

Gating methods for use in weld inspection systems

An automated system for non-destructively evaluating spot welds that includes at least one matrix phased array probe; a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe; and an enclosure that includes at least one input for connecting to the at least one matrix phased array probe, ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input, at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and at least one output for outputting the discrete specifications of evaluated welds.

Automated weld inspection system with weld acceptability pass or fail indications

A system for inspecting the surface of a curved object is provided. This system includes an object having a curved surface; at least one substantially flat interdigital transducer, wherein the interdigital transducer is operative to generate surface energy waves; and at least one coupling device disposed between the curved surface and the substantially flat interdigital transducer, wherein the coupling device is operative to conform to the curved surface, support the interdigital transducer, and provide a medium through which the surface energy waves can effectively travel from the interdigital transducer to the curved surface and across the curved surface in a predetermined direction.

Acoustic coupling shoes for use in inspecting non-flat surfaces

A system for characterizing a spot weld including an acoustic probe that further includes a plurality of ultrasonic transducer elements arranged in a curved array, wherein the transducer elements are operative to generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions; a phased array excitation unit coupled to the array of transducer elements for ultrasonically exciting transducer elements; and a controller coupled to the phased array excitation unit for controlling the operation of the phased array unit, gathering and processing information from the ultrasonic transducers, and generating a two-dimensional, color coded image that characterizes the integrity of the spot weld.

Three-dimensional matrix phased array spot weld inspection system

A portable system for non-destructively characterizing spot welds that includes at least one matrix phased array probe and a body, wherein the body is designed to be hand-held and further includes an ergonomically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.

Growing community of inventors

Centerville, OH, United States of America

Jeong K Na