Trw Limited

Thomas Derkacs

Istvan M Matay

Charles W Fetheroff

Istvan J Toth

John Touhalisky

Stephan D Murphy

An array of ultrasonic transducer (A) are disposed along a circular arc for examining tubular objects moving therethrough. A calibrating apparatus (B) includes a calibrating cylinder (22) having a plurality of calibrating flaws (24, 26) therein. A rotary positioning device (30) and an axial positioning device (40) adjust the relative spatial relationship of each calibration flaw and transducer. An ultrasonic control instrument (50) produces an echo signal having components corresponding to echoes received from the examined object. A computer (60) includes a gate adjustment control subroutine (66) which selectively separates a preselected component from the echo signal. A pulse amplitude measurement subroutine (64) measures the amplitude of the preselected echo signal component and, first, determines the peak amplitude of the component and, second, compares the amplitude of the component with a preselected standard. A position control subroutine (68), first, serially brings each calibration flaw generally into a preselected spatial relationship with each transducer and, second, adjusts the flaw/transducer spatial relationship until the pulse amplitude measurement subroutine detects the peak amplitude of the selected component. The spatial position of the peak amplitude is recorded in memory as an indication of the actual transducer location. A calibration subroutine (62) adjusts the gain and distance amplitude control adjustments of the ultrasonic instrument until the pulse amplitude measurement subroutine determines that the selected component matches the preselected standard.

Reference standard for calibration of ultrasonic arrays

A first array (A) of ultrasonic transducers transmits ultrasonic shear waves circumferentially around an examined cylindrical object (110). A second array (B) transmits ultrasonic shear waves axially along the examined object. Triggering pulses from a triggering amplifier (22) are switched by a multiplexer (24) to each individual transducer of the first and second arrays. As one of the transducers assumes the role of a transmitting transducer and transmits an ultrasonic wave, the other transducers of the first and second arrays assume a receiving mode to receive reflected ultrasonic components. A wave travel timer (26) measures the duration for an ultrasonic wave to be transmitted from the transmitting transducer to a defect and for a reflected component to propagate from the defect to the receiving transducer. A microprocessor (20) tri-angulates or otherwise computes the location and orientation of a reflective defect from the measured travel time, the spatial relationship of the transmitting and receiving transducers, and the direction of propagation of the transmitted ultrasonic wave.

Phased array inspection of cylindrical objects

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 of an inch (1.5 mils) despite unanticipated process variations.

Airfoil

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 inches (1.5 mils) despite unanticipated process variations.

Growing community of inventors

Mayfield, OH, United States of America

Thomas Derkacs