Wrinkle characterization and performance prediction for composite structures
First Claim
1. A method for calibrating an ultrasonic inspection system, comprising:
- (a) forming a multiplicity of reference standards made of composite material, each reference standard having at least one wrinkle;
(b) collecting ultrasonic B-scan data from the multiplicity of reference standards in respective areas using an ultrasonic inspection system;
(c) cutting the reference standards in the respective areas to expose respective cross sections;
(d) imaging the exposed cross sections to produce a respective optical cross section for each reference standard;
(e) measuring features of the at least one wrinkle of each reference standard which appear in the optical cross sections to acquire optical cross-section measurement data;
(f) for each reference standard, correlating the ultrasonic B-scan data collected in the respective area where the reference standard was cut with the optical cross-section measurement data acquired from the respective optical cross section to produce a respective wrinkle profile characterization for each reference standard; and
(g) using a computer to calculate dimensions of the wrinkle based on the ultrasonic B-scan data taking into account the correlation of the ultrasonic B-scan data to optical cross section measurement data established in step (f).
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Abstract
Methods that provide wrinkle characterization and performance prediction for wrinkled composite structures using automated structural analysis. In accordance with some embodiments, the method combines the use of B-scan ultrasound data, automated optical measurement of wrinkles and geometry of cross-sections, and finite element analysis of wrinkled composite structure to provide the ability to assess the actual significance of a detected wrinkle relative to the intended performance of the structure. The disclosed method uses an ultrasonic inspection system that has been calibrated by correlating ultrasonic B-scan data acquired from reference standards with measurements of optical cross sections (e.g., micrographs) of those reference standards.
25 Citations
20 Claims
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1. A method for calibrating an ultrasonic inspection system, comprising:
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(a) forming a multiplicity of reference standards made of composite material, each reference standard having at least one wrinkle; (b) collecting ultrasonic B-scan data from the multiplicity of reference standards in respective areas using an ultrasonic inspection system; (c) cutting the reference standards in the respective areas to expose respective cross sections; (d) imaging the exposed cross sections to produce a respective optical cross section for each reference standard; (e) measuring features of the at least one wrinkle of each reference standard which appear in the optical cross sections to acquire optical cross-section measurement data; (f) for each reference standard, correlating the ultrasonic B-scan data collected in the respective area where the reference standard was cut with the optical cross-section measurement data acquired from the respective optical cross section to produce a respective wrinkle profile characterization for each reference standard; and (g) using a computer to calculate dimensions of the wrinkle based on the ultrasonic B-scan data taking into account the correlation of the ultrasonic B-scan data to optical cross section measurement data established in step (f). - View Dependent Claims (2, 3, 4, 5)
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- 6. An ultrasonic imaging system having a B-scanning mode in which time and depth axes ranges and time-gate settings for a B-scan window are based on a correlation of ultrasonic B-scan data acquired in an area of a reference standard made of composite material with optical cross-section measurement data acquired from an image of a cross section of the reference standard made by cutting the area where the ultrasonic B-scan data was acquired.
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9. A method for non-destructive inspection of composite structures, comprising:
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(a) calibrating an ultrasonic inspection system based on a correlation of ultrasonic B-scan data acquired in an area of a reference standard made of composite material with optical cross-section measurement data acquired from an image of a cross section of the reference standard made by cutting the area where the ultrasonic B-scan data was acquired, each reference standard having at least one wrinkle; (b) collecting non-destructive inspection data from a part made of composite material using the ultrasonic inspection system after completion of step (a); (c) detecting the presence of a wrinkle in the part based on the non-destructive inspection data collected in step (b); (d) collecting ultrasonic B-scan data from the part using the ultrasonic inspection system; and (e) calculating dimensions of the wrinkle in the part based on the ultrasonic B-scan data collected in step (d) using a computer that takes into account the correlation of the ultrasonic B-scan data with the optical cross section measurement data. - View Dependent Claims (10, 11, 12, 13)
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14. A method for non-destructive inspection of composite structures, comprising:
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(a) calibrating an ultrasonic inspection system based on a correlation of ultrasonic B-scan data acquired in an area of a reference standard made of composite material with optical cross-section measurement data acquired from an image of a cross section of the reference standard made by cutting the area where the ultrasonic B-scan data was acquired, each reference standard having at least one wrinkle; (b) collecting ultrasonic B-scan data from a part made of composite material using the ultrasonic inspection system after completion of step (a); (c) detecting the presence of a wrinkle in the part based on the ultrasonic B-scan data collected in step (b); and (d) calculating dimensions of the wrinkle in the part based on the ultrasonic B-scan data collected in step (b) using a computer that takes into account the correlation of the ultrasonic B-scan data with the optical cross section measurement data. - View Dependent Claims (15, 16, 17)
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18. A method for predicting performance of a wrinkled composite structure, comprising:
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(a) calibrating an ultrasonic inspection system based on a correlation of ultrasonic B-scan data acquired in an area of a reference standard made of composite material with optical cross-section measurement data acquired from an image of a cross section of the reference standard made by cutting the area where the ultrasonic B-scan data was acquired, each reference standard having at least one wrinkle; (b) collecting ultrasonic B-scan data from a wrinkled composite structure using the ultrasonic inspection system after completion of step (a); (c) calculating dimensions of a wrinkle in the wrinkled composite structure based on the ultrasonic B-scan data collected in step (b) using a computer that takes into account the correlation of the ultrasonic B-scan data with the optical cross section measurement data to obtain wrinkle feature measurements; (d) generating a structural model of the wrinkled composite structure based on the wrinkle feature measurements obtained in step (c); and (e) performing a structural analysis of the structural model. - View Dependent Claims (19, 20)
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Specification