Methods and systems for determining bond efficacy using metallic reflectors and ultrasonic inspection

• US 10,641,744 B2
• Filed: 04/30/2018
• Issued: 05/05/2020
• Est. Priority Date: 04/30/2018
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Bolton, Joseph, Humfeld, Keith
• Primary Examiner(s): Nath, Suman K
• Application Number:
  US15/967,111
• Publication Number:
  US 20190331647A1
• Time in Patent Office: 736 Days
• Field of Search: 73588, 73583, 73597, 73598, 73599, 73600
• CPC Class Codes: G01N 2291/015 Attenuation, scattering
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0251 Solidification, icing, curing composites, polymerisation
• CPC Class Codes: G01N 2291/045 External reflections, e.g. on reflectors
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/4427 with stored values, e.g. threshold values
• CPC Class Codes: G01N 29/4436 with a reference signal amplitude comparison G01N29/48

Abstract

In an example, a method of determining bonding efficacy of a composite laminate is described. The method includes disposing a metallic substance on a bonding agent, coupling the bonding agent having the metallic substance between a first and second layer of composite material to form a composite assembly, heating and curing the composite assembly to produce the composite laminate, receiving a post-curing interference signal that indicates a post-curing degree of constructive interference resulting from transmission of ultrasonic waves into the composite laminate, comparing the post-curing interference signal to a pre-curing interference signal that indicates a baseline degree of constructive interference resulting from transmission of ultrasonic waves into the composite assembly, and determining the bond efficacy of the composite laminate based on the comparison, where a reduction in constructive interference between the pre-curing interference signal and the post-curing interference signal is indicative of the bond efficacy.

Claims

1. A method of determining bond efficacy of a composite laminate, the method comprising steps of:

disposing a metallic substance on a bonding agent;

coupling the bonding agent having the metallic substance between a first layer of composite material and a second layer of composite material to form a composite assembly;

heating and curing the composite assembly to produce the composite laminate;

transmitting ultrasonic waves into the composite laminate;

receiving a post-curing interference signal that indicates a post-curing degree of constructive interference resulting from the step of transmitting the ultrasonic waves into the composite laminate;

comparing the post-curing interference signal to a pre-curing interference signal that indicates a baseline degree of constructive interference resulting from transmission of ultrasonic waves into the composite assembly; and

determining the bond efficacy of the composite laminate based on comparing the post-curing interference signal to the pre-curing interference signal, wherein a reduction in constructive interference between the pre-curing interference signal and the post-curing interference signal is indicative of the bond efficacy.

2. The method of claim 1, wherein the step of disposing the metallic substance on the bonding agent comprises a step of disposing the metallic substance on an adhesive film.

3. The method of claim 1, wherein the step of disposing the metallic substance on the bonding agent comprises a step of disposing a metallic ink on the bonding agent.

4. The method of claim 1, wherein the step of disposing the metallic substance on the bonding agent comprises a step of disposing the metallic substance in one or more concentric circles.

5. The method of claim 4, further comprising:

determining a radius of each one of the one or more concentric circles such that distances, from a reference location on a surface of the composite assembly to every point along each one of the one or more concentric circles are substantially equal to one another, and wherein;

transmission of ultrasonic waves, having a particular wavelength, into the composite assembly at the reference location causes the baseline degree of constructive interference to occur, and

the step of disposing the metallic substance in the one or more concentric circles comprises a step of disposing the metallic substance in the one or more concentric circles such that each one of the one or more concentric circles has the radius determined for that one of the one or more concentric circles.

6. The method of claim 4, wherein the step of disposing the metallic substance in the one or more concentric circles comprises a step of disposing the metallic substance such that the metallic substance in at least one of the one or more concentric circles forms a continuous circular region.

7. The method of claim 4, wherein the step of disposing the metallic substance in the one or more concentric circles comprises a step of disposing the metallic substance such that the metallic substance in at least one of the one or more concentric circles forms a plurality of discrete regions arranged in a circular path.

8. The method of claim 7, wherein each of the plurality of discrete regions, arranged in the circular path, has a diameter between 10 and 500 nanometers.

9. The method of claim 7, wherein each of the plurality of discrete regions, arranged in the circular path, has a diameter between 1 and 50 micrometers.

10. The method of claim 1, wherein the step of comparing the post-curing interference signal to the pre-curing interference signal comprises steps of:

determining a ratio of the pre-curing interference signal to the post-curing interference signal; and

comparing the ratio to a threshold of the bond efficacy.

11. The method of claim 1, further comprising a step of:

before the step of heating and curing the composite assembly to produce the composite laminate, receiving the pre-curing interference signal that indicates the baseline degree of constructive interference resulting from the transmission of ultrasonic waves into the composite assembly.

12. A system comprising:

a computing device having a processor and memory that stores instructions, executable by the processor to;

cause a transducer to transmit ultrasonic waves into a composite assembly, wherein the composite assembly comprises a bonding agent inserted between a first layer of composite material and a second layer of composite material, and wherein a metallic substance is disposed on the bonding agent;

receive a pre-curing interference signal that indicates a baseline degree of constructive interference resulting from the ultrasonic waves being transmitted into the composite assembly;

cause the transducer to transmit ultrasonic waves into a composite laminate produced by heating and curing the composite assembly;

receive a post-curing interference signal that indicates a post-curing degree of constructive interference resulting from transmission of ultrasonic waves into the composite laminate;

compare the post-curing interference signal to the pre-curing interference signal; and

determine a bond efficacy of the composite laminate based on comparing the post-curing interference signal to the pre-curing interference signal, wherein a reduction in constructive interference between the pre-curing interference signal and the post-curing interference signal is indicative of the bond efficacy.

13. The system of claim 12, wherein the metallic substance is disposed on the bonding agent in one or more concentric circles.

14. The system of claim 13, wherein:

the instruction to cause the transducer to transmit ultrasonic waves into the composite assembly comprises an instruction to cause the transducer to transmit ultrasonic waves having a particular wavelength into the composite assembly at a reference location on a surface of the composite assembly,

a radius of each one of the one or more concentric circles is selected such that distances from the reference location to every point along each one of the one or more concentric circles are substantially equal to one another, and

the instruction to cause the transducer to transmit ultrasonic waves having the particular wavelength into the composite assembly at the reference location causes the baseline degree of constructive interference to occur.

15. The system of claim 13, wherein the metallic substance in at least one of the one or more concentric circles forms a continuous circular region.

16. The system of claim 13, wherein the metallic substance in at least one of the one or more concentric circles forms a plurality of discrete regions, arranged in a circular path.

17. The system of claim 12, wherein the instruction to compare the post-curing interference signal to the pre-curing interference signal comprises instructions to:

determine a ratio of the pre-curing interference signal to the post-curing interference signal; and

compare the ratio to a threshold of the bond efficacy.

18. A non-transitory computer readable medium having stored thereon instructions that, when executed by one or more processors of a computing device, cause the computing device to perform functions, comprising:

causing a transducer to transmit ultrasonic waves into a composite assembly, wherein the composite assembly comprises a bonding agent inserted between a first layer of composite material and a second layer of composite material, and wherein a metallic substance is disposed on the bonding agent;

receiving a pre-curing interference signal that indicates a baseline degree of constructive interference resulting from ultrasonic waves being transmitted into the composite assembly;

causing the transducer to transmit ultrasonic waves into a composite laminate produced by heating and curing the composite assembly;

receiving a post-curing interference signal that indicates a post-curing degree of constructive interference resulting from the transmission of ultrasonic waves into the composite laminate;

comparing the post-curing interference signal to the pre-curing interference signal; and

determining a bond efficacy of the composite laminate based on comparing the post-curing interference signal to the pre-curing interference signal, wherein a reduction in constructive interference between the pre-curing interference signal and the post-curing interference signal is indicative of the bond efficacy.

19. The non-transitory computer readable medium of claim 18, wherein:

the metallic substance is disposed on the bonding agent in one or more concentric circles,

the function of causing the transducer to transmit ultrasonic waves into the composite assembly comprises a function of causing the transducer to transmit ultrasonic waves having a particular wavelength into the composite assembly at a reference location on a surface of the composite assembly,

a radius of each one of the one or more concentric circles is selected such that distances from the reference location to every point along each one of the one or more concentric circles are substantially equal to one another, and

the function of causing the transducer to transmit ultrasonic waves having the particular wavelength into the composite assembly at the reference location causes the baseline degree of constructive interference to occur.

20. The non-transitory computer readable medium of claim 18, wherein the function of comparing the post-curing interference signal to the pre-curing interference signal comprises functions of:

determining a ratio of the pre-curing interference signal to the post-curing interference signal; and

comparing the ratio to a threshold of the bond efficacy.