The Boeing Company

John Z Lin

Hong Hue Tat

Russell Lee Keller

Kelly M Greene

Carlyn R Brewer

Richard Henry Bossi

Brice Aaron Johnson

Sayata Ghose

Samuel Francis Pedigo

Gary E Georgeson

James C Kennedy

Yuan-Jye Wu

Jill Paisley Bingham

James B Castle

Arne Kenneth Lewis

James E Pillers

Kane M Mordaunt

McKay Alma Kunz

Lauren K Lundquist

Sebastian Nervi

Wayne L Cooper

Sadie Lee Fieni

Cong Nghiep Duong

Nicolette P Yovanof

Mark Daniel Winters

John M Pryor

Clayton M Little

Kathryn T Moore

Mckay A Kunz

Mark D Winters

Hue Tat Hong

Sadie L Fieni

Sataya Ghose

Disclosed herein a method of producing an ultrasound that includes defining a set of criteria for an ultrasound emitter comprising a plate. The set of criteria includes a power output criterion, a frequency criterion and number of nodes for a resonance mode of the plate, a focus criterion, and a durability criterion. The method includes determining an outline and a thickness range for the plate, based on the set of criteria. The method includes using topology optimization to determine internodal zone dimensions for the plate, based on the set of criteria, the outline, and the thickness range. The method includes manufacturing the plate according to the internodal zone dimensions.

High-power ultrasound emitter design

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

Closed-loop systems and methods for controlling the temperature at the compaction point as an automated fiber placement (AFP) machine is placing material over complex surface features at varying speeds. The closed-loop system starts with multiple infrared temperature sensors directed at the layup surface in front of the compaction roller and also at the new layup surface behind the compaction roller. These sensors supply direct temperature readings to a control computer, which also receives speed data and a listing of active tows from the AFP machine and is also programmed with the number of plies in the current layup. In accordance with one embodiment, the heater control system uses a proportional-integral-derivative loop to control the temperature at the compaction point (e.g., at the interface of the compaction roller and a newly laid tow) and regulate the heater power to achieve the desired temperature.

Heater system for fiber placement machine

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

An example computer-implemented method of assessing damage to a structure includes receiving information of damage to the structure, and identifying a damage type for the damage. Following, the damage type and the information is compared with a first reference having allowable damage limits of the structure for that damage type, a second reference having damage repair information and associated damage repair processes, and a database having historical repair information for the damage type. Based on the damage type and the information indicating that the damage is outside the allowable damage limits described in the first reference and also does not have any associated damage repair process described in the second reference and the database does not include historical repair information for the damage type, expanded repair information is provided for a repair solution based on a material type and loading of the structure.

Methods and systems for assessing damage to a structure and determining repair information

Method and apparatus are provided for processing and changing the physical characteristics of a metal workpiece into a final metal component. Predetermined processing parameters are established for achieving a final metal component. The metal workpiece is positioned securely on a support during the changing of the physical characteristics. Impacts are applied to a surface of the workpiece multiple times for achieving the final metal component while controlling the impacting with the predetermined processing parameters. A sensor is provided for continuously sensing the currently existing physical conditions of the workpiece during impacting. The predetermined processing parameters are changed into adjusted processing parameters and the impacts are changed in reaction to the currently existing physical conditions of the workpiece from the sensing and processing of the workpiece until the final metal component has been achieved.

Control feedback loop for real-time variable needle peen forming

An apparatus is provided that includes a wave generator, plurality of transducers and processing device. The wave generator may be configured to simultaneously generate a plurality of acoustic waves that propagate through a laminate along a plurality of in-plane directions. The transducers may be spaced apart from one another and positionable at one or more known distances from the wave generator along respective in-plane directions. The transducers may be configured to detect acoustic waves propagating through the laminate along the respective in-plane directions. The processing device may be coupled to the transducers and configured to simultaneously calculate a plurality of elastic constants of the laminate as a function of velocities of the acoustic waves detected by the transducers. And the processing device may be configured to calculate the velocities as a function of the known distance(s) and arrival times of the acoustic waves at the transducers.

Apparatus and a method for measuring in-plane elastic constants for a laminate

A first simulated inspection is conducted to provide a first waveform data set associated with the at least one irregularity parameter. The first simulated inspection is conducted using a first evaluation setting. A first image is produced based on the first waveform set, and it is determined whether a quality of the first image satisfies a predetermined threshold.

Ultrasonic modeling for inspection of composite irregularities

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Renton, WA, United States of America

John Z Lin