The Boeing Company

Theboeing Company

Yuan-Jye Wu

Hong Hue Tat

Stephen Robert Poteet

Gary E Georgeson

Morteza Safai

James E Engel

William R Ferng

Matthew Todd Grimshaw

Robert E Cranfill

Anne S-w Kao

Daniel James Wright

Mostafa Rassaian

Rodney Stephen Wright

Taisia Tsukruk Lou

Vladimir Balabanov

Talion Edwards

Richard Henry Bossi

Dejan Nikic

Robert Alan Smith

David Keith Mefford

Joseph D Schaefer

Anne Kao

Fredrick Baden Holt

Olaf Weckner

Mary J Mathews

Anne Shu-Wan Kao

Daniel John Pierce

Mark Daniel Winters

Victor P Pauca

Rongzhong Li

James C Kennedy

William Talion Edwards

Jill Paisley Bingham

John Z Lin

Benjamin Emerson Carl Koltenbah

Christopher R Loesche

Sadie Lee Fieni

Vicki Wu

Andrew James Booker

Kari P Larkin

John M Pryor

John-Paul Nathaniel Sabino

Abdelhai Maysara Saadi

Clayton M Little

Zachary Robert Meves

Mark Thomas Greaves

Michelle Keim Condliff

D Dean Billheimer

Anuj K Adhikaram

Chelsey Elizibeth Henry

Jeremy Robert Larkin

Kathryn T Moore

Matthew G Pike

Mark D Winters

Hue Tat Hong

Sadie L Fieni

John-Paul N Sabino

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

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 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 system comprises a model generation system and an analyzer. The model generation system is configured to modify a model of a laminated composite structure to meet a user defined objective and to meet at least one of user defined performance constraints or user defined manufacturing constraints by changing at least one ply characteristic of at least one ply of the model while maintaining ply boundary geometry constraints for each ply of the model. The ply boundary geometry constraints of the model generation system include a number of defined ply boundary geometries each described by a respective mathematical function. The analyzer is configured to return objective values or constraint function values for at least one ply of the model.

Controlling and adjusting ply shapes of laminated composite structures for performance and manufacturing considerations

A system for quantifying x-ray backscatter system performance is disclosed. The system includes one or more x-ray backscatter detectors, an x-ray tube, a support, and a plurality of rods mounted on the support and arranged in groups. Each group of rods includes at least two rods having the same width. The system also includes a user interface configured to connect to the x-ray backscatter detectors to receive a backscatter signal from the x-ray backscatter detectors associated with the x-ray tube, where the user interface plots a modulation transfer function representing x-ray backscatter for each rod of the plurality of rods from x-rays transmitted by the x-ray tube.

System and method for quantifying x-ray backscatter system performance

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

A system for quantifying x-ray backscatter system performance may include a support; a plurality of rods mounted on the support; the rods of the plurality of rods arranged parallel to each other, having generally curved outer surfaces, and being arranged in groups of varying widths, each group of the groups having at least two of the rods of a same width; and a user interface configured to be connected to receive a backscatter signal from an x-ray backscatter detector associated with an x-ray tube, apply a transfer function to generate a transfer curve representing x-ray backscatter for each rod of the plurality of rods from x-rays transmitted by the x-ray tube.

System and method for quantifying X-ray backscatter system performance

The present disclosure provides a system, method, and apparatus for compressing and extracting features. The method involves transmitting at least one ultrasound signal into an object at a plurality of different locations on the object. Each of the locations is denoted by an x location and a y location. The method further involves receiving at least one waveform response signal. Also, the method involves generating a three-dimensional (3D) data cube with an X dimension, a Y dimension, and a time dimension. At least one waveform response signal is stored within the 3D data cube at the x location and the y location that is associated with the waveform response signal(s). Further, the method involves transforming at least one waveform response signal of the 3D data cube to produce at least one transformed signal.

Compression and feature extraction from full waveform ultrasound data

Composite skin-stringer structures which reduce or eliminate the risk of delamination at the skin-stringer interface. This can be accomplished by arranging ply directions (i.e., the angles of the fiber paths of the ply) in a layup in a way such that for the dominant loading, the skin and stringer will each deform in a way that reduces relative opening (fracture Mode I) and/or sliding (fracture Mode II) and/or scissoring (fracture Mode III) at the skin-stringer interface. This is possible when coupling between specific deformations modes is purposefully activated instead of being suppressed. The ply directions in the stringer are adjusted so that the stringer deforms in a controlled fashion to suppress or 'close' cracks that are about to form&#x2014;before the undesirable modes of failure form&#x2014;as load is applied.

Skin-stringer design for composite wings

A method of generating an optimized design model for a composite laminate may include computing a normalized set of lamination parameters and laminate stiffness matrices of an initial laminate design, and determining, using an optimizer operating on a finite element model, optimum values for the lamination parameters and the laminate thickness. The method may further include adjusting the optimum value of the laminate thickness, and performing an inversion process extracting multiple solutions from the lamination parameters, each solution including a unique set of individual fiber angles for each ply and representing an optimized design model of the composite laminate.

System and method for designing composite laminates using lamination parameters

A method and apparatus for analyzing an object using acoustic emissions. Load data is received for the object. Acoustic waveform data is received for the object from an acoustic sensing system. The acoustic waveform data represents acoustic emissions emanating from the object and is detected using the acoustic sensing system. A plurality of bins is created for the load data. A plurality of frequency distribution functions is generated for the plurality of bins using the acoustic waveform data. A set of learning algorithms is applied to the plurality of frequency distribution functions and the acoustic waveform data to generate an output that allows an operator to more easily and quickly assess a structural integrity of the object.

Example systems and methods are described for validating a manufacturing tolerance of a structure. A method includes receiving a digital image of a cross-section of the structure at an interface of a computing device, identifying an outer boundary of the structure from the digital image, selecting a region of the outer boundary based on changes in a first derivative or a second derivative of points of the outer boundary, identifying a geometry feature of the region of the outer boundary by comparison to stored templates of geometry features of the structure, making a comparison of the geometry feature of the region of the outer boundary to a manufacturing specification for a corresponding portion of the structure, and determining whether the structure is within a manufacturing tolerance based on the comparison of the geometry feature to the manufacturing specification.

Methods and systems to analyze optical images for quantification of manufacturing part quality

A method for inspecting a composite structure includes acquiring an image of the composite structure. The composite structure includes at least a first ply and a second ply adjacent the first ply. The method also includes transforming the image into a binary image, and determining a first boundary line between the first ply and the second ply. The method further includes characterizing an irregularity in the composite structure based at least partially on the first boundary line.

Methods and systems for inspection of composite irregularities

Growing community of inventors

Issaquah, WA, United States of America

Yuan-Jye Wu