Infrared imaging of ultrasonically excited subsurface defects in materials

• US 6,236,049 B1
• Filed: 09/16/1999
• Issued: 05/22/2001
• Est. Priority Date: 09/16/1999
• Status: Expired due to Term

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Wayne State University
• Inventors: Sun, Gang, Han, Xiaoyan, Ouyang, Zhong, Thomas, Robert L., Favro, Lawrence D., Sui, Hua
• Primary Examiner(s): Hannaher, Constantine
• Assistant Examiner(s): Gabor, Otilia
• Application Number:
  US09/397,585
• Time in Patent Office: 614 Days
• Field of Search: 250/341.6, 250/334, 250/338.1, 250/338.3
• US Class Current: 250/341.6
• CPC Class Codes: G01N 2291/02483 Other human or animal parts, e.g. bones
• CPC Class Codes: G01N 2291/02881 Temperature
• CPC Class Codes: G01N 2291/101 one transducer
• CPC Class Codes: G01N 2291/2638 Complex surfaces
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 25/72 Investigating presence of flaws
• CPC Class Codes: G01N 29/228 related to high temperature conditions
• CPC Class Codes: G01N 29/2412 using the magnetostrictive properties of the material to be examined, e.g. electromagnetic acoustic transducers [EMAT]; investigating the presence of flaws using eddy currents G01N27/90, magnetostrictive transducers B06B1/08, measuring magnetostrictive properties G01R33/18
• CPC Class Codes: G01N 29/2462 Probes with waveguides, e.g. SAW devices
• CPC Class Codes: G01N 29/28 providing acoustic coupling , e.g. water impedance matching G10K11/02
• CPC Class Codes: G01N 29/346 with amplitude characteristics, e.g. modulated signal
• CPC Class Codes: G01N 29/348 with frequency characteristics, e.g. single frequency signals, chirp signals measuring frequency of mechanical vibrations or acoustic waves in general G01H1/06, G01H3/04; measuring frequency or analysing frequency spectra G01R23/00
• CPC Class Codes: G01N 29/449 Statistical methods not provided for in G01N29/4409, e.g. averaging, smoothing and interpolation
• CPC Class Codes: G01N 29/46 by spectral analysis, e.g. Fourier analysis or wavelet analysis spectral signal processing per se G06F17/14

Abstract

A thermal imaging system for detecting cracks and defects in a component. An ultrasonic transducer is coupled to the specimen through a malleable coupler. Ultrasonic energy from the transducer causes the defects to heat up, which is detected by a thermal camera. The ultrasonic energy is in the form of a pulse where the frequency of the ultrasonic signal is substantially constant within the pulse. A control unit is employed to provide timing and control for the operation of the ultrasonic transducer and the camera.

Claims

1. A thermal imaging system for detecting defects in a component, said system comprising:

a sound source;

a thermal imaging camera directed towards the component and generating thermal images of the component; and

a controller electrically connected to the sound source and the camera, said controller causing the sound source to emit at least one pulse of a sound signal at a predetermined frequency and for a predetermined duration, and causing the camera to generate sequential images of the component, wherein the frequency of the sound signal has a substantially constant amplitude, and wherein vibrational energy from the sound source causes the defects in the component to heat up and be visible in the images generated by the camera.

2. The system according to claim 1 wherein the at least one pulse is a plurality of pulses separated by a predetermined time, and wherein the controller averages images taken within a predetermined window in each pulse, where the window is provided at the same delay time in each pulse from when the pulse is initiated.

3. The system according to claim 1 wherein the at least one pulse is a series of pulses, and wherein the system employs a box car integration technique to provide signal averaging of the images.

4. The system according to claim 1 wherein the sound source emits the pulse for a duration of one-half of a second or less.

5. The system according to claim 1 further comprising a coupler positioned between and in contact with the component and the sound source.

6. The system according to claim 5 wherein the coupler is malleable and is softer than an end of the sound source in contact with the coupler.

7. The system according to claim 5 wherein the coupler is a thin piece of metal.

8. The system according to claim 7 wherein the coupler is a copper member.

9. The system according to claim 1 further comprising a monitor responsive to the images from the camera, said monitor displaying the images.

10. The system according to claim 1 wherein the camera is directed towards the component at a location that is separate from the location where the sound source contacts the component.

25. The system according to claim 1 wherein the sound source is an ultrasonic transducer and the at least one pulse is an ultrasonic pulse.

11. A defect detection system for detecting defects in a structure, said system comprising:

a sound source for directing at least one pulse of a sound signal into the structure for a predetermined period of time, said signal having a predetermined frequency and a substantially constant amplitude;

a camera directed towards the structure and generating images of the structure when the source emits the sound signal; and

a controller connected to the source and the camera to provide timing signals therebetween, said controller being responsive to the images from the camera.

12. The system according to claim 11 wherein the at least one pulse is a plurality of pulses separated by a predetermined time, and wherein the system averages images taken within a predetermined window in each pulse, where the window is provided at the same delay time in each pulse from when the pulse is initiated.

13. The system according to claim 11 wherein the at least one pulse is a series of pulses, and wherein the system employs a box car integration technique to provide signal averaging of the images.

14. The system according to claim 11 wherein the sound source emits the pulse for a duration of one-half of a second or less.

15. The system according to claim 11 further comprising a coupler positioned in contact with the structure and the source, said coupler being a malleable member.

16. The system according to claim 15 wherein the coupler is a thin piece of metal.

17. The system according to claim 11 wherein the controller causes the camera to take sequential images of the structure before, during and after when the sound source emits the sound signal.

18. The system according to claim 11 wherein the camera is directed towards the structure at a location that is separate from a location where the source contacts the structure.

26. The system according to claim 11 wherein the sound source is an ultrasonic source and the sound signal is an ultrasonic signal.

19. A method of detecting defects in a structure, said method comprising the steps of:

emitting at least one pulse of a sound signal into the structure to heat the defects, said signal having a predetermined frequency and a substantially constant amplitude; and

generating a sequence of thermal images of the structure prior to, during and after the emission of the sound signal.

20. The method according to claim 19 further comprising the steps of emitting a plurality of pulses of the sound signal, and providing signal averaging of images generated in a window in each separate pulse where the window is provided at the same delay time in each pulse from when the pulse is initiated.

21. The method according to claim 19 further comprising the step of processing the images using a box car synchronous imaging technique.

22. The method according to claim 19 wherein the step of emitting a pulse of the sound signal includes emitting the pulse for a duration of one-half of a second or less.

23. The method according to claim 19 further comprising the step of providing a coupler in contact with the structure and in contact with a sound source that generates the sound signal.

24. The method according to claim 23 wherein the step of providing a coupler includes providing a coupler that is malleable and conforms to an end of the sound source in contact with the structure.

27. The method according to claim 19 wherein the step of emitting at least one pulse includes emitting at least one pulse of ultrasonic energy.

28. A defect detection system for detecting defects in a structure, said system comprising:

a sound source;

a coupler positioned between and in contact with the structure and the sound source;

a thermal imaging camera directed towards the structure, and generating thermal images of the structure; and

a controller electrically coupled to the sound source and the camera, said controller causing the sound source to emit a sound signal at a predetermined frequency for a predetermined duration, the signal having a substantially constant amplituide, and causing the camera to generate sequential images of the structure, wherein the sound signal from the sound source causes the defects in the structure to heat up and be visible in the images generated by the camera.

The limitation that the sound signal has a substantially constant amplitude was necessary to overcome any application of the prior art.

29. The system according to claim 28 wherein the coupler is malleable and is softer than an end of the sound source.

30. The system according to claim 29 wherein the coupler is a thin piece of metal.

31. The system according to claim 30 wherein the coupler is a copper member.