Structural bond inspection

• US 10,048,230 B2
• Filed: 11/14/2013
• Issued: 08/14/2018
• Est. Priority Date: 11/14/2013
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Stewart, Alan F., Tat, Hong H., Bossi, Richard H.
• Primary Examiner(s): Caputo, Lisa
• Assistant Examiner(s): Sinha, Tarun
• Application Number:
  US14/080,753
• Publication Number:
  US 20150128709A1
• Time in Patent Office: 1,734 Days
• Field of Search: 73588, 73643, 73587
• CPC Class Codes: G01N 19/04 Measuring adhesive force between materials, e.g. of sealing tape, of coating
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/045 by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks measuring resonant frequency G01H13/00; measuring strength properties by application of mechanical stress G01N3/00
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/14 using acoustic emission techniques echo of particles G01N29/046; measuring mechanical vibrations or acoustic waves in solids in general G01H1/00

Abstract

A method for determining the presence of damage in a structure includes applying energy to the structure to induce tension shockwaves in the structure. The method also includes detecting sound waves caused by the tension shockwaves using at least one acoustic emission sensor on the surface of the structure. Additionally, the method includes determining the presence of damage in the structure due to the applied energy based on detected sound waves.

Claims

1. A method for determining a presence of damage in a bond of a structure, comprising:

applying a first energy, a second energy, and a third energy comprising at least one laser beam to an excitation region of the structure with a wave form induction tool in slidable contact with a surface of the structure to induce first, second, and third tension shockwaves in the structure, wherein the second energy is a higher energy than the first energy and the third energy;

detecting first, second, and third sound waves caused by the first, second, and third tension shockwaves using at least two acoustic emission sensors in contact with the surface of the structure, the at least two acoustic emission sensors independent from one another and one of the at least two acoustic emission sensors is positioned a first distance apart from the excitation region and the other of the at least two acoustic emission sensors is positioned at a second distance apart from the excitation region, the first distance is different from the second distance, wherein the first energy, the second energy, and the third energy are applied at the surface of the structure at a position between the at least two acoustic emission sensors; and

determining the presence of damage in the bond of the structure due to the applied energy based on a comparison between the detected first and third sound waves and a variation between the first and third sound waves detected from the comparison.

2. The method of claim 1, wherein detecting the sound waves comprises detecting frequency characteristics of the sound waves, and determining the presence of damage in the structure is based on detected frequency characteristics of the sound waves.

3. The method of claim 2, wherein the frequency characteristics comprise a change in a characteristic frequency associated with the structure when no damage is present, and wherein the presence of the change in the characteristic frequency indicates damage in the structure.

4. The method of claim 1, further comprising estimating expected sound waves, and wherein determining the presence of damage in the structure comprises comparing the expected sound waves with detected sound waves.

5. The method of claim 4, wherein the expected sound waves are estimated based on characteristics of applied energy to the structure.

6. The method of claim 1, wherein the detected sound waves are analyzed to produce a Fast Fourier Transform pattern.

7. The method of claim 1, wherein at least one of the at least two acoustic emission sensors is slidable along the surface of the structure.

8. The method of claim 1, wherein applying energy to the structure induces compression shockwaves, and wherein the compression shockwaves convert into the tension shockwaves upon reflection off a surface of the structure.

9. The method of claim 1, further comprising assessing a minimal strength of the structure based on the determination of whether damage in the structure is present.

10. The method of claim 1, wherein the structure comprises a bonded structure, and wherein damage in the structure comprises delamination.

11. The method of claim 1, wherein the structure comprises first and second layers each made from a composite material or a composite material and a metal, and wherein damage is defined as separation of an adhesive layer between and adjoining the first and second layers.

12. The method of claim 1, wherein:

applying energy to the structure comprises applying a first low energy to the bonded structure to induce the first tension shockwaves, applying a second high energy to the bonded structure to induce the second tension shockwaves, and applying a third low energy to the bonded structure to induce the third tension shockwaves;

detecting sound waves comprises detecting the first sound waves caused by the first tension shockwaves, the second sound waves caused by the second tension shockwaves, and the third sound waves caused by the third tension shockwaves; and

determining the presence of damage in the bonded structure due to the applied energy comprises comparing the first sound waves to the third sound waves.

13. The method of claim 12, wherein a variation between a frequency pattern of the first sound waves and a frequency pattern of the third sound waves indicates the presence of damage in the bonded structure.

14. A system for concurrently determining strength of a bonded structure and presence of disbonds in the bonded structure, comprising:

a wave induction tool that transmits a laser beam onto the bonded structure, when in slidable contact with a surface of the bonded structure, to induce first, second, and third shockwaves in the bonded structure, wherein the second shockwave is stronger than the first and third shockwave;

a sound wave sensing device comprising at least two acoustic emission sensors that detects first, second, and third sound waves induced by the first, second, and third shockwaves, respectively, the sound wave sensing device being in direct contact with the surface of the bonded structure, the at least two acoustic emission sensors independent from one another and positioned a distance apart from each other on each side of the wave induction tool with at least one of the at least two acoustic emission sensors in slidable contact with the surface of the structure, wherein a first of the at least two acoustic emission sensors is a first distance away from a shockwave induction region in the bonded structure and a second of the at least two acoustic emission sensors is a second distance away from the shockwave induction region, wherein the first distance is different than the second distance, wherein the wave induction tool transmits the laser beam at a position on the surface between the at least two acoustic emission sensors; and

a controller that determines the presence of disbonds in the bonded structure based on a variation of characteristics of the first and third sound waves detected by the sound wave sensing device, and determining the strength of the bonded structure based on the presence of disbonds in the bonded structure.

15. The system of claim 14, wherein the wave induction tool is slidable along the surface of the bonded structure and at least one of the at least two acoustic emission sensors of the sound wave sensing device is non-movably coupled to the surface of the bonded structure and positioned at a distance apart to allow the wave induction tool to pass between the at least two acoustic emission sensors of the source wave sensing device.

16. The system of claim 14, wherein the wave induction tool and the at least two acoustic emission sensors of the sound wave sensing device are in slidable contact with the surface of the bonded structure, and wherein the sound wave sensing device is integrally mounted in the wave induction tool.

17. The system of claim 14, wherein the strength of the bonded structure corresponds with a strength of the shockwave necessary to create a disbond in the bonded structure.

19. The apparatus of claim 17, wherein the acoustic emission detection module is configured to determine the presence of a disbond in the bonded structure based on at least one characteristic of the laser beam transmitted onto the bonded structure.

18. An apparatus for concurrently testing strength of a bonded structure and determining a presence of disbonds in the bonded structure, comprising:

a laser bond inspection module configured to command a transmission of a laser beam, from a wave form induction tool in slidable contact with a surface of the bonded structure, onto an excitation region of the bonded structure to induce first, second, and third shockwaves in the bonded structure, wherein the second shockwave is stronger than the first and third shockwave;

at least two acoustic emission sensors in contact with the surface of the bonded structure, the at least two acoustic emission sensors independent from one another and positioned in contact with the surface of the bonded structure a distance apart from each other with at least one of the at least two acoustic emission sensors positioned at a first distance from the excitation region and the other of the at least two acoustic emission sensors positioned at a second distance apart from the excitation region with the first distance being different from the second distance, wherein the energies are applied at the surface of the structure at a position between the at least two acoustic emission sensors; and

an acoustic emission detection module configured to determine the presence of a disbond in the bonded structure and verify a strength of the bond based on at least one frequency characteristic of first, second, and third sound waves in the bonded structure induced by the first, second, and third shockwaves, respectively, the first, second, and third sound waves being detected by the at least one acoustic emission sensor.