Crack detection in thick-walled cylinders

• US 8,818,746 B1
• Filed: 03/25/2011
• Issued: 08/26/2014
• Est. Priority Date: 03/26/2010
• Status: Active Grant

• Current Assignee: United States Secretary of the Army
• Original Assignee: The United States Of America As Represented By The Secretary Of The Army
• Inventors: Johnson, Mark A., Hussain, Moayyed A., Troiano, Edward J.
• Primary Examiner(s): Kundu, Sujoy
• Assistant Examiner(s): Lee, Paul D
• Application Number:
  US13/071,691
• Time in Patent Office: 1,250 Days
• Field of Search: 702/35, 702/39, 702/54, 702/71, 702/76, 702/77, 702/141, 702/190
• US Class Current: 702/77
• CPC Class Codes: G01N 21/952 Inspecting the exterior surface of cylindrical bodies or wires G01N21/956 takes precedence
• CPC Class Codes: G01N 2203/006 Crack, flaws, fracture or rupture
• CPC Class Codes: G01N 29/045 by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks measuring resonant frequency G01H13/00; measuring strength properties by application of mechanical stress G01N3/00
• CPC Class Codes: G01N 29/14 using acoustic emission techniques echo of particles G01N29/046; measuring mechanical vibrations or acoustic waves in solids in general G01H1/00
• 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 simple, inexpensive, and fast method of establishing if a defect does or does not exist within a thick-walled solid geometry, which is especially useful to detect if such a defect, a crack, exists within a gun barrel. With further analysis, the method allows not only the identification of the defect'"'"'s presence; but, a means of establishing the size thereof—which, for example, is critical to understanding if a gun tube has a defect that would warrant its being taken out of service for the safety of its crew or removed from manufacturing. The method involves creating an acoustic vibration in the particular thick-walled, solid geometry, esp. a gun barrel, and observing the vibration pattern which results. The size of the particular defect can be ascertained by a) manually using a correlation between the magnitude of the defect and the relative changes in the decay coefficient or shifts in frequency data or (b) automatically using a Bayes maximum likelihood, statistical pattern classification algorithm and a library comprised of either the decay coefficients or the means and covariances of defect-free and cracked objects.

Claims

1. A method for establishing the size of a defect in a thick-walled, cylindrical geometry comprising, (1) creating an acoustic vibration in that geometry;

(2) detecting the vibration which results;

(3) filtering that signal, to remove extrinsic noise; and

(4) analyzing, on a general purpose computer, the resulting frequency pattern of the vibration by (a) using a Fourier transform to decompose the filtered frequency signal into its constituent major frequencies or spectrum;

(b) computing the decay coefficient of the time series data; and

(5) using a Bayes maximum likelihood statistical pattern classification algorithm to compare this decay coefficient to a library containing the decay coefficients of similar thick-walled, cylindrical geometries with varying size cracks therein, to determine the particular crack size thereof by correlating with the library data.

2. The method for establishing the size of a defect in a thick-walled, cylindrical geometry of claim 1, wherein said thick-walled, cylindrical geometry is a gun barrel.

3. The method for establishing the size of a defect in a thick-walled, cylindrical geometry of claim 2, wherein said gun barrel is the gun barrel selected from the group consisting of a 105 mm, a 120 mm, a 155 mm, a 175 mm, and a 203 mm artillery gun barrel.

4. The method for establishing the size of a defect in a thick-walled, cylindrical geometry of claim 2, wherein the acoustic vibration within the gun barrel is created by the firing of the gun.

5. The method for establishing the size of a defect in a thick-walled, cylindrical geometry of claim 2, wherein the acoustic vibration within the gun barrel is created by striking the barrel with a hammer.

6. The method for establishing the size of a defect in a thick-walled, cylindrical geometry of claim 1, wherein said detecting the vibration is by means of two or more accelerometers located circumferentially around the outside diameter of the cylindrical geometry.