Abstract: A method for quantitatively evaluating the expected ultrasonic inspectability of a designed part using ray tracing. First, a model of a part imported. Materials having different indices of refraction are selected for the part and an acoustic coupling medium. Then the following structures and positional relationships are defined: an ultrasonic transducer array comprising a plurality of elements, a position of the acoustic coupling medium between the transducer array and the part, and a plurality of positions of a transmit aperture relative to the part. For each defined position of the transmit aperture, a path of a respective ray is traced from a center of the transmit aperture through the part and then to a respective receive location on the transducer array. Also, a respective value of an inspectability margin is calculated based at least in part on a respective distance between a center of the receive aperture and the respective receive location.

Abstract: A method for quantitatively evaluating the expected ultrasonic inspectability of a designed part using ray tracing. First, a model of a part imported. Materials having different indices of refraction are selected for the part and an acoustic coupling medium. Then the following structures and positional relationships are defined: an ultrasonic transducer array comprising a plurality of elements, a position of the acoustic coupling medium between the transducer array and the part, and a plurality of positions of a transmit aperture relative to the part. For each defined position of the transmit aperture, a path of a respective ray is traced from a center of the transmit aperture through the part and then to a respective receive location on the transducer array. Also, a respective value of an inspectability margin is calculated based at least in part on a respective distance between a center of the receive aperture and the respective receive location.

Abstract: Methods and scan systems for analyzing an object. The methods include obtaining a local operation dataset that includes a plurality of operation data points obtained from an object and a corresponding location, within the operation coordinate system, for each operation data point of the plurality of operation data points. The methods also include mapping the plurality of operation data points from the operation coordinate system to a global coordinate system for the object. The mapping includes mapping to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system, for each operation data point. The scan systems include a robot that performs a plurality of operations on an object within an operation coordinate system and a computing device that maps the plurality of operation data points from the operation coordinate system to a global coordinate system.

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.

Abstract: An infrared camera is directed aft of a compaction roller of a composite laying head. Heat is applied to a substrate by a heater mounted forward of the compaction roller. Infrared images are captured of composite tows laid down on a substrate by the compaction roller. Whether the composite tows have sufficient contact is determined using the infrared images.

Abstract: A method of detecting a compound in a material sample is presented. A transformation is generated from a set of IR spectra of a set of identified compounds, in which the compound is one of the set of identified compounds. The transformation is applied to an IR spectrum of the material sample to form a transformed IR spectrum. A decomposition is applied to the transformation. Results indicative of a presence or an absence of the compound are generated based on an output of the decomposition.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A method of detecting a compound in a material sample is presented. A transformation is generated from a set of IR spectra of a set of identified compounds, in which the compound is one of the set of identified compounds. The transformation is applied to an IR spectrum of the material sample to form a transformed IR spectrum. A decomposition is applied to the transformation. Results indicative of a presence or an absence of the compound are generated based on an output of the decomposition.

Abstract: A system and method combine ablation of a surface of a part with inspection of the internal integrity of the part. A laser may direct an ablative laser pulse at the surface of the part sufficient to remove a portion of material from the part surface and to cause the part to produce an ultrasound waveform. A positioning system may provide relative movement of the ablative laser pulse and the part for application of a series of ablative laser pulses at a series of locations over an area of the surface of the part. An ultrasonic detection device may couple to the part to receive the ultrasound waveform and transmit it to a part inspection system that has stored a set of reference waveforms in a control computer. The system compares the ultrasound waveform to one or more of the reference waveforms to detect and characterize anomalies in the part.

Abstract: Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.

Abstract: An apparatus comprises an acoustic sensing system and an analyzer module. The acoustic sensing system is positioned relative to an object, wherein the acoustic sensing system detects acoustic emissions and generates acoustic waveform data for the acoustic emissions detected. The analyzer module is implemented in a computer system that receives load data and the acoustic waveform data for the object, generates a plurality of frequency distribution functions using the acoustic waveform data, and generates a frequency distribution function time evolution image containing a plurality of points of each of the plurality of frequency distribution functions.

Abstract: In an example, a method for forming a composite part includes, based on a part specification, cutting layers of material in a sequence and positioning the layers to form a stack. For each layer, after positioning the layer and before cutting a next layer in the sequence, the method includes (i) scanning along a length of the layer to determine an image, (ii) determining, based on the image, at least two edges of the layer, (iii) determining, based on the edges, a measured width at locations along the length of the layer, (iv) comparing the measured width at each location to a target width at the location, (v) deciding, based on the comparison, whether to adjust the production process, and (vi) if the decision is to adjust the production process, then adjusting the production process based on the comparison. The part specification specifies the target width at each location.

Abstract: A method of detecting a compound in a material sample is presented. A transformation is generated from a set of IR spectra of a set of identified compounds, in which the compound is one of the set of identified compounds. The transformation is applied to an IR spectrum of the material sample to form a transformed IR spectrum. A decomposition is applied to the transformation. Results indicative of a presence or an absence of the compound are generated based on an output of the decomposition.

Abstract: An infrared camera is directed aft of a compaction roller of a composite laying head. Heat is applied to a substrate by a heater mounted forward of the compaction roller. Infrared images are captured of composite tows laid down on a substrate by the compaction roller. Whether the composite tows have sufficient contact is determined using the infrared images.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A system and method combine ablation of a surface of a part with inspection of the internal integrity of the part. A laser may direct an ablative laser pulse at the surface of the part sufficient to remove a portion of material from the part surface and to cause the part to produce an ultrasound waveform. A positioning system may provide relative movement of the ablative laser pulse and the part for application of a series of ablative laser pulses at a series of locations over an area of the surface of the part. An ultrasonic detection device may couple to the part to receive the ultrasound waveform and transmit it to a part inspection system that has stored a set of reference waveforms in a control computer. The system compares the ultrasound waveform to one or more of the reference waveforms to detect and characterize anomalies in the part.

Abstract: Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Abstract: A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.