Abstract: Described herein is an apparatus for inspecting a component includes a first feature inspector with at least one wave transducer configured to inspect a first feature of the component. The first feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the first feature inspector relative to the first feature of the component. The apparatus further includes a second feature inspector with at least one wave transducer configured to inspect a second feature of the component. The second feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the second feature inspector relative to the second feature of the component.

Abstract: A multi-sensor NDI probe having means for self-alignment of the NDI sensors in conjunction with the movement of the sensor suite along the length of a hollow elongated stiffener having a rounded cap. The apparatus comprises a large-radius curved ultrasonic transducer array with cylindrical focus, which provides complete coverage for the rounded cap, two small-radius convex curved transducer arrays for NDI of the lower outside radii, and two linear transducer arrays for NDI of the sides of the stiffener. The five transducer arrays are supported by respective compliant assemblies which facilitate proper adjustment of the location (i.e., position and orientation) of the transducer arrays during scanning. The positions of the transducer arrays are adjusted to account for geometric variations in the stiffener.

Abstract: Described herein is an apparatus for inspecting a component includes a first feature inspector with at least one wave transducer configured to inspect a first feature of the component. The first feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the first feature inspector relative to the first feature of the component. The apparatus further includes a second feature inspector with at least one wave transducer configured to inspect a second feature of the component. The second feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the second feature inspector relative to the second feature of the component.

Abstract: A non-destructive inspection (NDI) device is described that includes a robotic arm, a storage device proximate the robotic arm, and a plurality of NDI probe assemblies disposed within the storage device. Each NDI probe assembly includes at least one transducer operable for NDI of a part and a tool operable as a mechanical interface between the robotic arm and the corresponding NDI probe assembly. Each NDI probe assembly is configured for a specific NDI task, for NDI of a part, and the robotic arm is operable for selectively engaging the tools and movement of the probe assemblies for the NDI of at least a portion of a part.

Abstract: A multi-sensor NDI probe having means for self-alignment of the NDI sensors in conjunction with the movement of the sensor suite along the length of a hollow elongated stiffener having a rounded cap. The apparatus comprises a large-radius curved ultrasonic transducer array with cylindrical focus, which provides complete coverage for the rounded cap, two small-radius convex curved transducer arrays for NDI of the lower outside radii, and two linear transducer arrays for NDI of the sides of the stiffener. The five transducer arrays are supported by respective compliant assemblies which facilitate proper adjustment of the location (i.e., position and orientation) of the transducer arrays during scanning. The positions of the transducer arrays are adjusted to account for geometric variations in the stiffener.

Abstract: A non-destructive inspection (NDI) device is described that includes a robotic arm, a storage device proximate the robotic arm, and a plurality of NDI probe assemblies disposed within the storage device. Each NDI probe assembly includes at least one transducer operable for NDI of a part and a tool operable as a mechanical interface between the robotic arm and the corresponding NDI probe assembly. Each NDI probe assembly is configured for a specific NDI task, for NDI of a part, and the robotic arm is operable for selectively engaging the tools and movement of the probe assemblies for the NDI of at least a portion of a part.

Abstract: A non-destructive inspection (NDI) device is described that includes a robotic arm, a storage device proximate the robotic arm, and a plurality of NDI probe assemblies disposed within the storage device. Each NDI probe assembly includes at least one transducer operable for NDI of a part and a tool operable as a mechanical interface between the robotic arm and the corresponding NDI probe assembly. Each NDI probe assembly is configured for a specific NDI task, for NDI of a part, and the robotic arm is operable for selectively engaging the tools and movement of the probe assemblies for the NDI of at least a portion of a part.

Abstract: A non-destructive inspection (NDI) device is described that includes a robotic arm, a storage device proximate the robotic arm, and a plurality of NDI probe assemblies disposed within the storage device. Each NDI probe assembly includes at least one transducer operable for NDI of a part and a tool operable as a mechanical interface between the robotic arm and the corresponding NDI probe assembly. Each NDI probe assembly is configured for a specific NDI task, for NDI of a part, and the robotic arm is operable for selectively engaging the tools and movement of the probe assemblies for the NDI of at least a portion of a part.

Abstract: A nondestructive inspection apparatus and method for inspecting a structure having an interior opening portion may comprise an inspection apparatus outer probe unit having a plurality of outer probe unit walls each having a surface corresponding to a respective one of the plurality of exterior surfaces of a respective structure wall, the outer probe unit may comprise a first outer probe member and a second outer probe member, magnetically coupled to each other through magnetic attraction between a magnet on the first outer probe unit member and a magnet on the second outer probe unit member; and a magnetic balance positioned to force the second outer probe unit member in a direction of increased magnetic coupling of the second outer probe unit member to the first outer probe unit member through magnetic repulsion between a magnet on the magnetic balance and a magnet on the second outer probe unit member.

Abstract: A system for performing ultrasonic testing on a composite part includes an ultrasonic transducer, a shoe for holding the transducer, and means for automatically adjusting position of the transducer during ultrasonic testing. The transducer position is adjusted to account for geometry variations in the part.

Abstract: A nondestructive inspection apparatus and method for inspecting a structure having an interior opening portion may comprise an inspection apparatus outer probe unit having a plurality of outer probe unit walls each having a surface corresponding to a respective one of the plurality of exterior surfaces of a respective structure wall, the outer probe unit may comprise a first outer probe member and a second outer probe member, magnetically coupled to each other through magnetic attraction between a magnet on the first outer probe unit member and a magnet on the second outer probe unit member; and a magnetic balance positioned to force the second outer probe unit member in a direction of increased magnetic coupling of the second outer probe unit member to the first outer probe unit member through magnetic repulsion between a magnet on the magnetic balance and a magnet on the second outer probe unit member.

Abstract: Ultrasonic testing on a part includes scanning the part while performing pulse echo and through transmission ultrasonic testing on the part; converting pulse echo data into time of flight (TOF) and amplitude channels, and converting through transmission data into a data representation that identifies porosity. The testing further includes analyzing the pulse echo TOF to identify locations of any anomalies in the part, and using loss of back (LOB) at each of the identified locations to discriminate low porosity from other anomalies.

Abstract: A system for performing ultrasonic testing on a composite part includes an ultrasonic transducer, a shoe for holding the transducer, and means for automatically adjusting position of the transducer during ultrasonic testing. The transducer position is adjusted to account for geometry variations in the part.

Abstract: Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support a plurality of inspection sensors typically arranged in an ordered matrix array and possibly with one or more additional inspection sensors aligned for inspection of difficult to inspect features of a structure such as radius corner or edge features. Rapid prototype integrated matrix array inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.

Abstract: Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder, which is configured to support one or more curved linear inspection sensors and may be constructed from rapid prototyping, such as stereolithography. Integrated curved linear ultrasonic transducer inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices and inspecting otherwise difficult-to-inspect curved radius features of structures, such as a corner of a hat stringer.

Abstract: Ultrasonic testing on a part includes scanning the part while performing pulse echo and through transmission ultrasonic testing on the part; converting pulse echo data into time of flight (TOF) and amplitude channels, and converting through transmission data into a data representation that identifies porosity. The testing further includes analyzing the pulse echo TOF to identify locations of any anomalies in the part, and using loss of back (LOB) at each of the identified locations to discriminate low porosity from other anomalies.

Abstract: Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support a plurality of inspection sensors typically arranged in an ordered matrix array and possibly with one or more additional inspection sensors aligned for inspection of difficult to inspect features of a structure such as radius corner or edge features. Rapid prototype integrated matrix array inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.

Abstract: Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support one or more linear inspection sensors. Rapid prototype integrated linear ultrasonic transducer inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.

Abstract: Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support a plurality of inspection sensors typically arranged in an ordered matrix array and possibly with one or more additional inspection sensors aligned for inspection of difficult to inspect features of a structure such as radius corner or edge features. Rapid prototype integrated matrix array inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.

Abstract: A hat stringer inspection device permits continuous inspection of hat stringers as one or more probes are moved along the length of the hat stringer. Probes may be magnetically coupled to opposing surfaces of the structure, including, for example, where one of the probes is positioned inside the hat stringer and the probes are magnetically coupled across the surface of the hat stringer. The device may be autonomous with a feedback-controlled motor to drive the inspection device along the hat stringer. Magnetic coupling is also used to re-orient the position and/or alignment of the probes with respect to changes in the hat stringer or shapes, sizes, and configurations of hat stingers.