System and method for real-time visualization of defects in a matertial
The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system includes a graphical user interface (GUI) capable of showing a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. The GUI is capable of displaying the 3-D image as each additional 2-D cross section is scanned by an ultrasonic testing apparatus in real time or near real time, including probable defect regions that contain a flaw such as a hole, crack, wrinkle, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting defect areas within the 3-D image in real time or near real time and providing data regarding each defect area, such as the depth, size, and/or type of each defect.
1. A system for visualizing defects within a test material, comprising:
a non-destructive testing device in communication with a processor and a graphical user interface (GUI);
wherein the processor receives signals from the non-destructive testing device corresponding to a test object and processes the signals to produce scan data;
wherein, based on the scan data, the processor generates at least one A-scan image, at least one B-scan image, and a plurality of C-scan images;
wherein the GUI is operable to display a three-dimensional (3-D) graphical representation of the test object, wherein at least one surface of the 3-D graphical representation is equivalent to one of the at least one B-scan image or the plurality of C-scan images; and
wherein the processor constructs and the GUI displays the 3-D graphical representation in real time, as the signals are received by the processor;
wherein the system is operable to automatically generate B-scan images of a foreign object and a corresponding depth from the surface of the test material for a B-scan image; and
wherein the system is operable to automatically align the plurality of C-scan images by centroids of a plurality of damage areas of each of the plurality of C-scan images.
2. The system of claim 1 , wherein the non-destructive testing device includes an ultrasonic transducer.
3. The system of claim 1 , wherein the GUI allows for the selection of which of the at least one A-scan image, the at least one B-scan image, the plurality of C-scan images, and the 3-D graphical representation to simultaneously display via the GUI and the GUI allows for the selection of the relative position of each selected element.
4. The system of claim 1 , wherein the 3-D graphical representation includes a first surface equivalent to a first B-scan, a second surface orthogonal to the first surface and equivalent to a second B-scan, and a third surface orthogonal to the first surface and second surface and equivalent to a C-scan.
5. The system of claim 1 , wherein before scanning and retrieving a full waveform for one or more A-scans of a material, a plurality of z-gate start times and a plurality of z-gate end times are selected, wherein the selection of the plurality of z-gate start times, the plurality of z-gate end times, or gate regions refers to which areas of the full waveform are analyzed, and wherein the processor generates a plurality of C-scans, and wherein each of the plurality of C-scans corresponds to one of the plurality of z-gate start times and one of the plurality of z-gate end times.
6. The system of claim 5 , wherein the non-destructive testing device performs a preliminary scan on the test object to produce preliminary scan data, wherein the plurality of z-gate start times and the plurality of z-gate end times are automatically selected based on the preliminary scan data.
7. The system of claim 1 , wherein the GUI is operable to receive a selected depth, and wherein the 3-D graphical representation only displays stacked C-scans corresponding to depths greater than the selected depth.
8. A system for visualizing defects within a test material, comprising:
a non-destructive testing device in communication with a processor and a graphical user interface (GUI);
wherein the processor receives full waveform signals from the non-destructive testing device corresponding to a test object and processes the signals to produce scan data;
wherein, based on the scan data, the processor generates at least one A-scan image, at least one B-scan image, and a plurality of C-scan images;
wherein the GUI is operable to display a three-dimensional (3-D) graphical representation of the test object, wherein at least one surface of the 3-D graphical representation is equivalent to one of the at least one B-scan image or one of the plurality of C-scan images;
wherein the system is operable to automatically identify a foreign object in the at least one B-scan image and determine a corresponding depth from the surface of the test material for the identified foreign object;
wherein the GUI allows for the selection of which of the at least one A-scan image, the at least one B-scan image, the plurality of C-scan images, and the 3-D graphical representation to simultaneously display via the GUI and the GUI allows for the selection of the relative position of each selected element; and
wherein the system is operable to automatically align the plurality of C-scan images by centroids of a plurality of damage areas of each of the plurality of C-scan images.
9. The system of claim 8 , wherein the non-destructive testing device includes an ultrasonic transducer.
10. The system of claim 8 , wherein the processor constructs and the GUI displays the 3-D graphical representation in real time, as the signals are received by the processor.
11. The system of claim 8 , wherein the 3-D graphical representation includes a first surface equivalent to a first B-scan, a second surface orthogonal to the first surface and equivalent to a second B-scan, and a third surface orthogonal to the first surface and second surface and equivalent to a C-scan.
12. The system of claim 8 , wherein before scanning, a plurality of z-gate start times and a plurality of z-gate end times are selected, wherein the processor generates a plurality of C-scans, and wherein each of the plurality of C-scans corresponds to one of the plurality of z-gate start times and one of the plurality of z-gate end times.
13. The system of claim 12 , wherein the non-destructive testing device performs a preliminary scan on the test object to produce preliminary scan data, wherein the plurality of z-gate start times and the plurality of z-gate end times are automatically selected based on the preliminary scan data.
14. The system of claim 12 , wherein the 3-D graphical representation is constructed by stacking the plurality of C-scans.
15. The system of claim 14 , wherein the GUI is operable to receive a selected depth, and wherein the 3-D graphical representation only displays stacked C-scans corresponding to depths greater than the selected depth.
16. A method for visualizing defects within a test material, comprising:
providing a non-destructive testing device in communication with a processor and a graphical user interface (GUI);
the processor receiving signals from the non-destructive testing device corresponding to a test object and processing the signals to produce scan data;
the processor generating, based on the scan data, at least one A-scan image, at least one B-scan image, and a plurality of C-scan images;
the GUI displaying a three-dimensional (3-D) graphical representation of the test object, wherein at least one surface of the 3-D graphical representation is equivalent to one of the at least one B-scan image or the plurality of C-scan images;
wherein the processor constructs and the GUI displays the 3-D graphical representation in real time, as the signals are received by the processor;
wherein before scanning and retrieving a full waveform for the at least one A-scan image, the system receives a selection of a plurality of z-gate start times and a plurality of z-gate end times, wherein the selection of the plurality of z-gate start times, and the plurality of z-gate end times determines which areas of the full waveform are analyzed, wherein the processor generates a plurality of C-scans, and wherein each of the plurality of C-scans corresponds to one of the plurality of z-gate start times and one of the plurality of z-gate end times; and
wherein the system is operable to automatically align the plurality of C-scan images by centroids of a plurality of damage areas of each of the plurality of C-scan images.
17. The method of claim 16 , wherein the GUI allows for the selection of which of the at least one A-scan image, the at least one B-scan image, the plurality of C-scan images, and the 3-D graphical representation to simultaneously display via the GUI and the GUI allows for the selection of the relative position of each selected element.
18. The method of claim 16 , wherein the non-destructive testing device includes an ultrasonic transducer.
19. The method of claim 16 , wherein the 3-D graphical representation includes a first surface equivalent to a first B-scan, a second surface orthogonal to the first surface and equivalent to a second B-scan, and a third surface orthogonal to the first surface and second surface and equivalent to a C-scan.