Systems and methods for thermographic inspection of composite structures

• US 7,287,902 B2
• Filed: 06/07/2005
• Issued: 10/30/2007
• Est. Priority Date: 06/07/2005
• Status: Expired due to Fees

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Georgeson, Gary E., Safai, Morteza, Thompson, Jeffrey G., Spalding, John F. Jr.
• Primary Examiner(s): GUADALUPE, YARITZA
• Application Number:
  US11/146,785
• Publication Number:
  US 20060274812A1
• Time in Patent Office: 875 Days
• Field of Search: 374 4- 7, 374/162, 374120-121, 374/57, 126/263
• US Class Current: 374/5
• CPC Class Codes: G01J 2005/0077 Imaging
• CPC Class Codes: G01N 25/72 Investigating presence of flaws

Abstract

Systems and methods for thermographically inspecting a composite material or honeycombed type structures are disclosed. In one embodiment, a system includes a thermal heat source configured to be either removably coupled to or positioned proximate to the composite material to generate a localized thermal field in a selected area of the composite material. A thermal imaging device generates a visible image of the generated thermal field.

Claims

1. A system for thermographically inspecting a composite material, comprising:

a thermal heat source configured to be at least one of engaged with and positioned proximate to the composite material to generate a localized thermal field in a selected area of the composite material; and

a thermal imaging device configured to generate a visible image of the thermal field, wherein the thermal heat source comprises an aqueous solution enclosed in a container.

2. The system of claim 1, wherein the thermal heat source further comprises an aqueous solution of a selected salt that is sealably enclosed in a container.

3. The system of claim 2, wherein the selected salt comprises at least one of sodium acetate and calcium nitrate tetrahydrate.

4. The system of claim 2, wherein the selected salt is formulated to achieve a solution temperature of at least 125 degrees Fahrenheit, and to maintain the solution temperature for at least one-half hour.

5. The system of claim 1, wherein the thermal heat source further comprises a reactant group that includes an oxidizer and a liquid fuel that are separated within a containment bag until activated.

6. The system of claim 5, wherein the oxidizer comprises potassium permanganate and the fuel includes a polyol.

7. The system of claim 5, wherein the reactant group is formulated to achieve a solution temperature of at least about 165 degrees, Fahrenheit.

8. The system of claim 1, wherein the thermal heat source further comprises a first side configured to reduce heat loss from the thermal heat source, and an opposing second side configured to be applied to a surface portion of the composite material.

9. System of claim 1, wherein the thermal heat source is adapted to emit heat generated by at least one of an exothermic chemical reaction and an exothermic phase change reaction.

10. The system of claim 1, wherein the thermal imaging device further comprises at least one of an optical thermal imager configured to detect long-wave electromagnetic radiation emitted by the thermal field, and a thermographic film that is configured to be coupled to a surface portion of the composite material and responsive to surface temperatures in the thermal field.

11. The system of claim 10, wherein the thermal imaging device comprises a thermographic film having a thermochromic liquid crystal film that is formulated to respond to the surface temperatures.

12. The system of claim 11, further comprising a thermal couplant interposed between the thermochromic liquid crystal film and the surface portion of the composite material.

13. The system of claim 11, wherein the thermochromic liquid crystal film further comprises a vacuum bag that may be evacuated to impress the liquid crystal film against the surface portion of the composite material.

14. A thermographic imaging kit for field inspecting a composite material, comprising:

a thermal heat source configured to transmit heat to the composite material to generate a localized thermal field in a selected area of the composite material following an activation of the source; and

a thermal imaging device configured to generate a visible image of the thermal field;

wherein the thermal heat source comprises at least one of an aqueous solution of a selected salt that is sealably enclosed in a containment bag, and a reactant group that includes an oxidizer and a liquid fuel that are separated within a containment bag until activated.

15. The thermographic imaging kit of claim 14, wherein thermal imaging device further comprises at least one of an infrared camera and a thermochromic liquid crystal film configured to be applied to a surface of the composite material.

16. The thermographic imaging kit of claim 14, further comprising a camera configured to record electromagnetic radiation at visible wavelengths, and a processor coupled to the infrared camera that is operable to process thermal data acquired by the infrared camera and to store the processed data in a memory device.