Portable laser/ultrasonic method for nondestructive inspection of complex structures

• US 5,698,787 A
• Filed: 04/12/1995
• Issued: 12/16/1997
• Est. Priority Date: 04/12/1995
• Status: Expired due to Term

• Current Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Original Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Inventors: Kintz, Kevin G., Reighard, Mark K., Parzuchowski, Halina M.
• Primary Examiner(s): Williams, Hezron E.
• Assistant Examiner(s): MOLLER, RICHARD ALAN
• Application Number:
  US08/420,501
• Time in Patent Office: 979 Days
• Field of Search: 73/643, 73/588, 73/583, 73/655, 73/657, 73/600, 73/635, 73/633, 73/640, 73/641, 356/429, 356/430, 356/431, 356/241, 356/237
• US Class Current: 73/643
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0289 Internal structure, e.g. defects, grain size, texture
• CPC Class Codes: G01N 2291/269 Various geometry objects
• CPC Class Codes: G01N 29/2418 using optoacoustic interaction with the material, e.g. laser radiation, photoacoustics photoacoustic cells G01N21/1702; measuring characteristics of vibrations by using radiation-sensitive means G01H9/00; acousto-optical conversion techniques for short-range imaging G01S15/8965; sound-producing devices using laser bundle G10K15/046
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material

Abstract

A method and apparatus for non-destructive inspection of complex structures employs a portable laser based ultrasonic transducer 600 output to rapidly detect and size flaws in such structures, including the radii of composites, laminates, and complex skin/substructure assemblies, such as airplane wings. A fiber optic delivery system 610A is employed with the laser based ultrasonic transducer 600 and a thermoelastic medium to rapidly and accurately access the radii of complex structures in the field without the need for liquid or gel couplants, with the thermoelastic expansion of the test piece 680 producing mechanical stresses that initiate detectable sound waves regardless of the angle of the laser based ultrasonic transducer 600 output with respect to the test piece 680. A MAUS III scanning device may be employed to detect these sound waves and provide accurate information as to the detected flaws.

Claims

1. An apparatus comprising:

at least one laser based ultrasonic transmitting, transducer means, and movable delivery means for delivering at least one incident, laser based ultrasonic transducer output to a test object so as to generate ultrasonic energy output for through transmission of said ultrasonic energy output in the test object, said laser based ultrasonic transmitting transducer means being connected to said movable delivery means for providing said incident laser based ultrasonic transducer output;

at least one movable, ultrasonic, receiving, transducer means mounted on the test object opposite said incident, laser based ultrasonic transducer output for receiving the through transmission of ultrasonic energy output from said incident, laser based ultrasonic transducer output in said test article, said receiving transducer means further comprising means for oscillating said receiving transducer means opposite said movable laser based ultrasonic transducer output, said receiving transducer means further producing an output representing the ultrasonic transmission through the test object from the laser based ultrasonic transducer output;

harmonic moving means for automatically and harmonically moving the incident laser based ultrasonic transducer output along one side of the test object, correlative to the movement of the receiving transducer means; and

means for detecting and displaying the position coordinates of any flaw in the test object which is identified as a result of a variation in the ultrasonic energy output transmitted through the test object.

2. An apparatus according to claim 1 wherein said means to deliver said movable laser based ultrasonic transducer output comprises an optical fiber laser based ultrasonic transducer output delivery assembly.

3. An apparatus according to claim 2 wherein said optical fiber laser based ultrasonic transducer output delivery assembly comprises an optical fiber held in place against the test object by a fiber optic guide shoe.

4. An apparatus according to claim 1 wherein said at least one movable, ultrasonic, receiving, transducer means comprises a piezoelectric receiving transducer.

5. An apparatus according to claim 1 wherein said harmonic moving means comprise a rigid connecting member between said incident laser based ultrasonic transducer output means and said receiving transducer means.

6. A method for nondestructively testing and determining the presence, location, and size of flaws in at least one juncture in a complex structure, comprising the steps of:

delivering to said at least one juncture at least one movable laser based ultrasonic transducer output from at least one laser based, transmitting transducer means, so as to generate ultrasonic energy output for through transmission of said ultrasonic energy output at said at least one juncture;

receiving said through transmission of said ultrasonic energy output by using at least one movable, ultrasonic, receiving, transducer means mounted on the complex structure opposite the incident laser based ultrasonic transducer output;

oscillating said receiving transducer opposite the movable laser based ultrasonic transducer output;

harmonically moving said movable, ultrasonic receiving transducer means and said movable laser based ultrasonic transducer output along the complex structure; and

detecting and displaying position coordinates of any flaw in said at least one juncture in a complex juncture, which is identified as a result of a variation in the ultrasonic energy output transmitted through said complex structure, by using means for detecting and displaying such position coordinates.

7. A method according to claim 6 wherein said delivering step comprises the step of delivering said movable laser based ultrasonic transducer output with an optical fiber, laser based ultrasonic transducer output delivery assembly.

8. A method according to claim 7 wherein said delivering step further comprises holding said optical fiber in said delivery assembly in place against said at least one juncture of said complex structure by a fiber optic guide shoe.

9. A method according to claim 6 wherein said receiving step comprises receiving said through transmission with at least one piezoelectric receiving transducer.

10. A method according to claim 6 wherein said harmonically moving step comprises harmonically moving said receiving transducer and said incident laser based ultrasonic transducer output with means comprising a rigid connecting member between the incident laser based ultrasonic transducer output means and the receiving transducer means.

11. A method according to claim 6 wherein said delivering step comprises delivering to a multiplicity of junctures of said complex structure, a multiplicity of movable laser based ultrasonic transducer outputs.

12. An apparatus for nondestructively testing and determining the presence, location, and size of flaws in a test object, comprising:

at least one laser based ultrasonic transmitting, transducer means;

means for delivering a movable, incident, laser based ultrasonic transducer output to said test object so as to generate ultrasonic energy output for through transmission of said ultrasonic energy output in said test object, said through transmission representing a characteristic of the internal composition of said test object;

at least one movable, ultrasonic, receiving, transducer means mounted on the test object opposite said movable, incident, laser based ultrasonic transducer output so as to receive the through transmission of ultrasonic energy output generated in the test object from said laser based ultrasonic transducer output, said receiving transducer means further comprising means for oscillating said receiving transducer means opposite said movable laser based ultrasonic transducer output, said receiving transducer means further producing an output representing the transmission from the laser based ultrasonic transducer transmitting transducer means;

harmonic moving means for automatically and harmonically moving said movable, incident, laser based ultrasonic transducer output correlative to the movement of the receiving transducer means;

positioning means for producing an integrated position output for both the incident laser based ultrasonic transducer output and the receiving transducer means, said integrated position output representing the position coordinates of the harmonically moving laser based ultrasonic transducer output and receiving transducer relative to the test object;

signal collating means for receiving the output of said receiving transducer and of said integrated position output, and for pairing said receiving transducer output with said integrated position output; and

indicating means responsive to said signal collating means for indicating the correlative relationship between said receiving transducer output and said integrated position output that have been paired.

13. An apparatus according to claim 12 wherein said laser based ultrasonic transmitting transducer means comprises a Nd:

YAG laser.

14. An apparatus according to claim 13 wherein said Nd:

YAG laser is connected to means to deliver at least one movable, incident, laser based ultrasonic transducer output that comprise an optical fiber, laser based ultrasonic transducer output delivery assembly.

15. An apparatus according to claim 14 wherein said optical fiber, laser based ultrasonic transducer output delivery assembly comprises an optical fiber held in place against the test object by a fiber optic guide shoe.

16. An apparatus according to claim 12 wherein said at least one movable, ultrasonic, receiving, transducer means comprises a piezoelectric receiving transducer.

17. An apparatus according to claim 12 wherein said harmonic moving means comprise a rigid connecting member between the incident laser based ultrasonic transducer output means and the receiving transducer means.

18. An apparatus for nondestructively testing and determining the presence, location, and size of flaws in at least one juncture in a test object, said at least one juncture having a radius region formed in the test object at the intersection of a skin attached to a stiffener, comprising:

at least one laser based ultrasonic transmitting, transducer means, and movable delivery means for delivering at least one incident, laser based ultrasonic transducer output to said radius region so as to generate ultrasonic energy output for through transmission of said ultrasonic energy output in the test object, said laser based ultrasonic transmitting transducer means being connected to said movable delivery means for providing said incident laser based ultrasonic transducer output;

at least one movable, ultrasonic, receiving, transducer means mounted on the skin opposite said incident, laser based ultrasonic transducer output for receiving the through transmission of ultrasonic energy output from said incident, laser based ultrasonic transducer output in said test article, said receiving transducer means further comprising means for oscillating said receiving transducer means opposite said movable laser based ultrasonic transducer output, said receiving transducer means further producing an output representing the ultrasonic transmission through the test object from the laser based ultrasonic transducer output;

harmonic moving means for automatically and harmonically moving the incident laser based ultrasonic transducer output along said radius region of the test object, correlative to the movement of the receiving transducer means; and

means for detecting and displaying the position coordinates of any flaw in the test object which is identified as a result of a variation in the ultrasonic energy output transmitted through the test object.

19. A method for nondestructively testing and determining the presence, location, and size of flaws in at least one juncture in a complex structure, said juncture having a radius region formed in the complex structure at the intersection of a skin attached to a stiffener, comprising the steps of:

delivering to said at least one juncture at least one movable laser based ultrasonic transducer output from at least one laser based, transmitting transducer means, so as to generate ultrasonic energy output for through transmission of said ultrasonic energy output at said at least one juncture;

receiving said through transmission of said ultrasonic energy output by using at least one movable, ultrasonic, receiving, transducer means mounted on the skin opposite the incident laser based ultrasonic transducer output;

harmonically moving said movable, ultrasonic receiving transducer means along the skin and said movable laser based ultrasonic transducer output along said radius region; and

detecting and displaying position coordinates of any flaw in said at least one juncture in a complex juncture, which is identified as a result of a variation in the ultrasonic energy output transmitted through said complex structure, by using means for detecting and displaying such position coordinates.