SYSTEM AND METHOD FOR REAL-TIME DEGREE OF CURE EVALUATION IN A 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 composite materials, comprising:
an ultrasonic transducer in communication with a processor and a display means;
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 ultrasonic transducer scans the test object while both the ultrasonic transducer and the test object are within a controlled thermal environment wherein the test object is being manufactured; and
wherein the system is operable to produce a 3D graphical image indicating areas of the test object that are undercured, overcured, or properly cured.
2 . The system of claim 1 , wherein the processor is operable to determine a cure state of more than one layer of the test object simultaneously.
3 . The system of claim 1 , wherein the controlled thermal environment is a furnace.
4 . The system of claim 1 , wherein temperature settings of the controlled thermal environment are adjusted based on a cure state of at least one layer of the test object.
5 . The system of claim 1 , wherein the system is operable to determine a cure state of at least one layer of the test object, and wherein the at least one layer is not the layer closest to the ultrasonic transducer.
6 . The system of claim 1 , wherein the ultrasonic transducer operates at a frequency between about 2.25 MHz and about 15 MHz.
7 . The system of claim 1 , wherein the ultrasonic transducer is movable relative to a central housing of the transducer housing assembly, and wherein moving the ultrasonic transducer relative to the central housing adjusts the focus of the ultrasonic transducer.
8 . The system of claim 1 , wherein the processor is operable to determine a cure state of the test object as a whole.
9 . A system for non-destructive testing of composite materials, comprising:
a plurality of ultrasonic transducers in communication with a processor and a display means;
wherein each of the plurality of ultrasonic transducers are operable to emit ultrasonic waves into and receive ultrasonic waves from a specific location on a test object to produce scan data;
wherein the ultrasonic transducer scans the test object while both the ultrasonic transducer and the test object are within a controlled thermal environment wherein the test object is being manufactured; and
wherein the system is operable to produce a 3D graphical image indicating areas of the test object that are undercured, overcured, or properly cured based on the average A-scan.
10 . The system of claim 9 , wherein the plurality of ultrasonic transducers are disposed within a coupling fluid-filled chamber of a transducer housing assembly.
11 . The system of claim 9 , wherein the processor is operable to determine a cure state of the test object as a whole.
12 . The system of claim 9 , wherein the system is operable to determine a cure state of at least one layer of the test object, and wherein the at least one layer is not the layer closest to the ultrasonic transducer.
13 . The system of claim 9 , wherein the at least one ultrasonic transducer is movable relative to a central housing of a portable transducer housing assembly, and wherein moving the at least one ultrasonic transducer relative to the central housing adjusts the focus of the at least one ultrasonic transducer.
14 . The system of claim 9 , wherein temperature settings of the controlled thermal environment are adjusted based on a cure state of at least one layer of the test object.
15 . The system of claim 9 , wherein the plurality of ultrasonic transducers operate at frequencies between about 2.25 MHz and about 15 MHz.
16 . A system for non-destructive testing of composite materials, comprising:
at least one ultrasonic transducer in communication with a processor and a display means;
wherein the at least one ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from one or more locations on a test object to produce scan data;
wherein the at least one ultrasonic transducer scans the test object while both the at least one ultrasonic transducer and the test object are within a controlled thermal environment wherein the test object is being manufactured;
wherein a cure state of the at least one layer of the test object is obtained by comparison to a differential scanning calorimetry (DSC) calibration curve; and
wherein the system is operable to produce a 3D graphical image indicating areas of the test object that are undercured, overcured, or properly cured.
17 . The system of claim 16 , wherein the at least one ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly.
18 . The system of claim 16 , wherein the at least one transducer operates at a frequency between about 2.25 MHz and about 15 MHz.
19 . The system of claim 16 , wherein the controlled thermal environment is a furnace.
20 . The system of claim 16 , wherein the at least one ultrasonic transducer is movable relative to a central housing of a portable transducer housing assembly, and wherein moving the at least one ultrasonic transducer relative to the central housing adjusts the focus of the at least one ultrasonic transducer.