Abstract: Disclosed herein is a probe for non-destructively inspecting a hat stiffener. The probe comprises a body, which comprises an inspection surface and a slot formed in the inspection surface. The probe also comprises an ultrasonic-sensor assembly that is fixed to the body and open to the inspection surface via the slot. The probe further comprises a surface-engagement assembly, which comprises a first foot and a second foot. The surface-engagement assembly is movably coupled to the body such that the first foot and the second foot are on opposite ends of the slot of the body and the first foot and the second foot are movable relative to the body and the ultrasonic-sensor assembly.

Abstract: Disclosed herein is a probe for non-destructively inspecting a hat stiffener. The probe comprises a body, which comprises an inspection surface and a slot formed in the inspection surface. The probe also comprises an ultrasonic-sensor assembly that is fixed to the body and open to the inspection surface via the slot. The probe further comprises a surface-engagement assembly, which comprises a first foot and a second foot. The surface-engagement assembly is movably coupled to the body such that the first foot and the second foot are on opposite ends of the slot of the body and the first foot and the second foot are movable relative to the body and the ultrasonic-sensor assembly.

Abstract: System and method for enabling ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective best return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected (i.e., predicted) surface as well as the full range of part surface variability.

Abstract: System and method for enabling ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective best return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected (i.e., predicted) surface as well as the full range of part surface variability.

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: System and method for enabling ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective best return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected (i.e., predicted) surface as well as the full range of part surface variability.

Abstract: A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.

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 probe is used to inspect the health of a corner radius within an elongate internal cavity of a structure. The probe is transported through the cavity on a carriage that maintains the probe a substantially constant distance from the corner radius as the carriage traverses changes in the cross sectional shape of the cavity.

Abstract: A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.

Abstract: System and method for enabling ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective best return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected (i.e., predicted) surface as well as the full range of part surface variability.

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 non-destructive inspection method, apparatus and system are provided for inspecting a workpiece having a curved surface with at least one predefined radius of curvature. The apparatus, such as an inspection probe, includes a plurality of transducer elements positioned in an arcuate configuration having a predefined radius of curvature and a curved delay line. The curved delay line has an outer arcuate surface having a predefined radius of curvature that matches the predefined radius of curvature of the transducer elements. The curved delay line also has an inner arcuate surface that has at least one predefined radius of curvature that matches the at least one predefined radius of curvature of the curved surface of the workpiece. In addition to the inspection probe, the system includes an excitative source for triggering the transducer elements to emit signals into the workpiece and a computing device to receive the return signals.

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: An ultrasonic probe performs non-destructive inspection of a corner radius of a part. According to one embodiment, an ultrasonic probe includes an ultrasonic sensor array, and a shoe for holding the sensor array and moving the sensor array along the radius of the part. The shoe includes means for adjusting the sensor array so all ultrasonic beams from the sensor array have the same water path distance to a center of the radius, and for adjusting the sensor array so that all beams pass through the center of the radius.

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 permit inspection of uniquely shaped structures such as fuselage frames and shear ties. Probes may be constructed from rapid prototyping. Inspection may be performed manually and may use a portable function support system for delivering fluid couplant, controlling transmit and receive functions of the inspection sensors, and delivering immediate visual analysis for an operator. Integrated ultrasonic inspection apparatus, systems, and methods facilitate fast and efficient custom inspection devices and inspecting otherwise difficult-to-inspect structures.

Abstract: A method of inspecting a radius area of composite parts with an ultrasonic inspection system, the system includes at least one ultrasonic probe, an upper sliding surface, a lower sliding surface, an adjustable guide rail, and an adjustable encoder wheel rotatably coupled to a rotary encoder, is provided. The method includes generating a high frequency sound wave using the probe including a radius of curvature extending from a center point, the sound wave travels partially through the part, adjusting the guide rail to align the center point of the probe with a center axis of a part corner portion, sliding the part through the inspection system to inspect the corner portion using the sound wave by rotating the wheel and rotary encoder such that the arcuate distance of the part is recorded, adjusting the wheel to avoid any apertures defined within the part, and processing the sound wave information.

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.