X-RAY SIDESCATTER INSPECTION OF LAMINATES

• US 20180202949A1
• Filed: 01/18/2017
• Published: 07/19/2018
• Est. Priority Date: 01/18/2017
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Smith, Nathan R.
• Granted Patent: US 10,393,680 B2
• Time in Patent Office: Days
• CPC Class Codes: G01N 2223/05 by diffraction, scatter or reflection
• CPC Class Codes: G01N 2223/052 reflection
• CPC Class Codes: G01N 2223/50 Detectors
• CPC Class Codes: G01N 2223/5015 linear array
• CPC Class Codes: G01N 2223/615 composite materials, multilayer laminates
• CPC Class Codes: G01N 2223/648 voids
• CPC Class Codes: G01N 23/20008 Constructional details of analysers, e.g. characterised by X-ray source, detector or optical system; Accessories therefor; Preparing specimens therefor monochromators for X- rays using crystals G21K1/06

Abstract

Systems and methods are provided for detecting gaps in composite parts. One method includes radiating a beam of x-rays in a firing direction towards surface of a multi-layer Carbon Fiber Reinforced Polymer (CFRP) part, acquiring data indicating intensity of sidescatter radiation received at an x-ray detector that extends along the CFRP part in the firing direction, and examining the acquired data for gaps at the CFRP part based on differences in intensity indicated by the data.

Claims

1. A method comprising:

radiating a beam of x-rays in a firing direction towards surface of a multi-layer Carbon Fiber Reinforced Polymer (CFRP) part;

acquiring data indicating intensity of sidescatter radiation received at an x-ray detector that extends along the CFRP part in the firing direction; and

examining the acquired data for gaps at the CFRP part based on differences in intensity indicated by the data.

2. The method of claim 1 further comprising:

placing the x-ray detector within a hole at the part, the hole extending across multiple layers, wherein the part is aligned such that the hole extends in the firing direction.

3. The method of claim 1 wherein:

radiating the beam results in the beam striking an area surrounding the hole; and

the x-ray detector engages in receiving sidescatter radiation along an entire circumference of the x-ray detector.

4. The method of claim 1 further comprising:

radiating the beam of x-rays in the firing direction via an x-ray source.

5. The method of claim 1 wherein:

the gaps comprise delaminations or voids between layers of the CFRP part.

6. The method of claim 1 further comprising:

interposing a radiation shield between the x-ray detector and an x-ray source, thereby blocking the beam from directly striking the x-ray detector.

8. The method of claim 1 further comprising:

identifying locations at the x-ray detector that have received amounts of sidescatter radiation that are higher than a threshold; and

determining that the locations correspond with gaps within the CFRP part.

9. The method of claim 1 further comprising:

identifying peaks in received sidescatter radiation along the firing direction; and

determining that the peaks indicate the presence of gaps in the CFRP part.

7. The method of 1 further comprising:

placing the x-ray detector along a side of the part that extends in the firing direction.

10. A method comprising:

identifying a region for inspection at a multi-layer Carbon Fiber Reinforced Polymer (CFRP) part;

drilling a hole that penetrates multiple layers of the CFRP part in the region;

inserting an x-ray detector into the hole;

radiating a beam of x-rays in the firing direction;

receiving sidescatter radiation at an x-ray detector as the beam penetrates the CFRP part;

acquiring data indicating intensity of sidescatter radiation received at the x-ray detector; and

examining the acquired data for gaps at the CFRP part based on differences in intensity indicated by the data.

11. The method of claim 10 further comprising:

utilizing a radiation shield to block the beam from directly striking the x-ray detector.

12. The method of claim 10 wherein:

radiating the beam results in the beam striking an area surrounding the hole; and

receiving sidescatter radiation at the x-ray detector comprises receiving sidescatter radiation along an entire circumference of the x-ray detector.

13. The method of claim 10 further comprising:

identifying locations at the x-ray detector that have received amounts of sidescatter radiation that are higher than a threshold; and

determining that the locations correspond with gaps between layers of the CFRP part.

14. The method of claim 10 further comprising:

identifying peaks in received sidescatter radiation along the firing direction; and

determining that the peaks indicate the presence of gaps in the CFRP part.

15. A system comprising:

an x-ray source that radiates a beam of x-rays in a firing direction towards a surface of a multi-layer Carbon Fiber Reinforced Polymer (CFRP) part for inspection;

an x-ray detector at the CFRP part that extends along the firing direction and receives sidescatter radiation as the beam penetrates the CFRP part; and

a controller that acquires data generated by the x-ray detector, and examines the acquired data for differences in intensity in the acquired data.

16. The system of claim 15 further comprising:

a radiation shield, interposed between the x-ray detector and the x-ray source, that blocks the beam from directly striking the x-ray detector.

17. The system of claim 15 further comprising:

the CFRP part, wherein the x-ray detector is placed along a side of the CFRP part that extends in the firing direction.

18. The system of claim 15 further comprising:

the CFRP part, wherein the x-ray detector is placed within a hole at the CFRP part, the hole extends across multiple layers, and the CFRP part is aligned such that the hole extends in the firing direction.

19. The system of claim 18 wherein:

the beam strikes an area surrounding the hole; and

the x-ray detector receives sidescatter radiation along an entire circumference of the x-ray detector.

20. The system of claim 15 wherein:

the controller identifies locations at the x-ray detector that have received amounts of sidescatter radiation that are higher than a threshold, and determines that the locations correspond with gaps between layers of the part.

21. The system of claim 15 wherein:

the detector comprises a digital x-ray detector.

22. The system of claim 15 wherein:

the controller identifies peaks in received sidescatter radiation along the firing direction, and determines that the peaks correspond with gaps between layers of the part.

23. The system of claim 15 wherein:

the detector comprises a circumferential x-ray detector.