SYSTEM AND METHOD FOR REAL-TIME VISUALIZATION OF DEFECTS IN A CURVED MATERIAL
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 non-destructive testing of curved test objects, comprising:
an ultrasonic transducer in communication with a processor and a display means;
wherein the ultrasonic transducer is not disposed within an immersion tank;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object to produce scan data;
wherein the surface of the test object is not substantially planar;
wherein the test object has a first curvature along a first direction and a second curvature along a second direction; and
wherein, based on the scan data, the processor is operable to determine a thickness of the test object at a plurality of locations on the test object.
2 . The system of claim 1 , wherein the processor is operable to automatically determine the thickness at the plurality of locations on the test object without use of a calibration block.
3 . The system of claim 1 , wherein the ultrasonic transducer operates at a frequency between about 5 MHz and about 15 MHz.
4 . The system of claim 1 , wherein the ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly.
5 . The system of claim 1 , wherein the processor is further operable to determine the thickness of one or more individual layers within the test object.
6 . The system of claim 1 , wherein the processor is further operable to determine a number of plies present at a plurality of locations on the test object.
7 . The system of claim 1 , wherein the first curvature and/or the second curvature spatially vary along the surface of the test object.
8 . The system of claim 1 , wherein the ultrasonic transducer is coupled to an offset probe, wherein the offset probe is operable to determine a relative position and/or angle of the ultrasonic transducer relative to a surface of the test object to produce offset data, and wherein an angle and/or a position of the ultrasonic transducer relative to the test object is automatically adjusted based on the offset data.
9 . A system for non-destructive testing of curved test objects, comprising:
an ultrasonic transducer in communication with a processor and a display means;
wherein the ultrasonic transducer is not disposed within an immersion tank;
wherein the ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object to produce scan data;
wherein the surface of the test object is not substantially planar; and
wherein, based on the scan data, the processor is operable to determine a thickness of the test object at a plurality of locations on the test object.
10 . The system of claim 9 , wherein the processor is operable to automatically determine the thickness at the plurality of locations on the test object without use of a calibration block.
11 . The system of claim 9 , wherein the ultrasonic transducer operates at a frequency between about 5 MHz and about 15 MHz.
12 . The system of claim 9 , wherein the processor is further operable to determine a number of plies present at a plurality of locations on the test object.
13 . The system of claim 9 , wherein the processor is further operable to determine the thickness of one or more individual layers within the test object.
14 . The system of claim 9 , wherein the test object has a first curvature along a first direction and a second curvature along a second direction.
15 . The system of claim 9 , wherein the processor is further operable to determine a ply orientation, a weave type, and/or a material of one or more individual layers of the test object.
16 . The system of claim 9 , wherein the ultrasonic transducer is coupled to an offset probe, wherein the offset probe is operable to determine a relative position and/or angle of the ultrasonic transducer relative to a surface of the test object to produce offset data, and wherein an angle and/or a position of the ultrasonic transducer relative to the test object is automatically adjusted based on the offset data.
17 . A system for non-destructive testing of curved test objects, comprising:
an ultrasonic transducer in communication with a processor and a display means;
wherein the ultrasonic transducer is not disposed within an immersion tank;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object to produce scan data;
wherein the surface of the test object is not substantially planar;
wherein, based on the scan data, the processor is operable to determine a thickness of the test object at a plurality of locations on the test object; and
wherein the ultrasonic transducer is coupled to an offset probe, wherein the offset probe is operable to determine a relative position and/or angle of the ultrasonic transducer relative to a surface of the test object to produce offset data, and wherein an angle and/or a position of the ultrasonic transducer relative to the test object is automatically adjusted based on the offset data.
18 . The system of claim 17 , wherein the ultrasonic transducer operates at a frequency between about 5 MHz and about 15 MHz.
19 . The system of claim 17 , wherein the ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly.
20 . The system of claim 17 , wherein the test object has a first curvature along a first direction and a second curvature along a second direction.