Abstract: A field deployable infrared imaging (FDIR) system and method for inspecting a composite component comprises a hand-held long-wave IR camera to capture a thermal image of the composite component, wherein the camera has an adjustable temperature control that captures an image with a 10 degree working range, a frame capture rate of at least 1 second for a length of time of not less than 90 seconds; and a processor for post-processing the thermal image using a second order derivative algorithm wherein the post-processed thermal image shows the defect better than the captured infrared image, and detects the one or more defects in the composite component.

Abstract: A method for mobile robotic based inspection includes delivery of inspection requirements identifying a part and one or more inspection mode types. A three-dimensional model of the part and one or more physical attributes or specifications of the aeronautical part are received. A plurality of different motion sequences for the robot inspection system are determined to evaluate a plurality of predefined points on the component using one or more sensors for the one or more inspection types. Data acquisition parameters are determined for inspection sequence to allow for collection of inspection data for one or more inspection modes. A motion sequence from the plurality of different motion sequences is selected based on one or more parameters. An optimized inspection program configured to update operating parameters of the robot inspection system to perform the selected motion sequence and capture data using the one or more sensors is generated.

Abstract: A field deployable infrared imaging (FDIR) system and method for inspecting a composite component comprises a hand-held long-wave IR camera to capture a thermal image of the composite component, wherein the camera has an adjustable temperature control that captures an image with a 10 degree working range, a frame capture rate of at least 1 second for a length of time of not less than 90 seconds; and a processor for post-processing the thermal image using a second order derivative algorithm wherein the post-processed thermal image shows the defect better than the captured infrared image, and detects the one or more defects in the composite component.

Abstract: A method of performing structural analysis relating to a component having CAD-based geometry, refined CAD-based geometry and CAD-based FEA data associated therewith. The method includes scanning the component to obtain scan-based point cloud geometry of the component, aligning the scan-based point cloud geometry with the CAD-based geometry of the component, generating scan-based geometry of the component by refining the scan-based point cloud geometry, comparing the scan-based geometry with the refined CAD-based geometry of the component to quantify geometric differences therebetween, generating scan-based FEA geometry of the component by meshing the scan-based geometry, performing finite element analysis on the scan-based FEA geometry to obtain scan-based FEA data and comparing the scan-based FEA data with the CAD-based FEA data of the component to quantify the effect of geometric difference therebetween.

Abstract: A system and method to inspect flaws associated with a part. The system includes a first image capturing device configured to capture a first set of images of the part and a computer operably associated with first image capturing device and configured to receive and analyze the first set of images. The method includes treating the part with a magnetic particle and fluorescent penetrant processing, capturing a first set of images of an outer surface of the part with the first image capturing device, and identifying a part defect with an algorithm associated with the computer.

Abstract: One aspect of a process to inspect a composite component includes traversing multiple ultrasonic probe array portions on respective multiple component surfaces of the composite component. The multiple component surfaces are either separate from or at angles to each other. The process includes simultaneously passing an ultrasonic signal into the multiple component surfaces through the multiple ultrasonic probe array portions. The process also includes receiving a response to the ultrasonic signal through the multiple ultrasonic probe array portions.

Abstract: A system and method to inspect flaws associated with a part. The system includes a first image capturing device configured to capture a first set of images of the part and a computer operably associated with first image capturing device and configured to receive and analyze the first set of images. The method includes treating the part with a nital etchant solution, capturing a first set of images of an outer surface of the part with the first image capturing device, and identifying a part defect with an algorithm associated with the computer.

Abstract: A method of performing structural analysis relating to a component having CAD-based geometry, refined CAD-based geometry and CAD-based FEA data associated therewith. The method includes scanning the component to obtain scan-based point cloud geometry of the component, aligning the scan-based point cloud geometry with the CAD-based geometry of the component, generating scan-based geometry of the component by refining the scan-based point cloud geometry, comparing the scan-based geometry with the refined CAD-based geometry of the component to quantify geometric differences therebetween, generating scan-based FEA geometry of the component by meshing the scan-based geometry, performing finite element analysis on the scan-based FEA geometry to obtain scan-based FEA data and comparing the scan-based FEA data with the CAD-based FEA data of the component to quantify the effect of geometric difference therebetween.

Abstract: A method for mobile robotic based inspection includes delivery of inspection requirements identifying a part and one or more inspection mode types. A three-dimensional model of the part and one or more physical attributes or specifications of the aeronautical part are received. A plurality of different motion sequences for the robot inspection system are determined to evaluate a plurality of predefined points on the component using one or more sensors for the one or more inspection types. Data acquisition parameters are determined for inspection sequence to allow for collection of inspection data for one or more inspection modes. A motion sequence from the plurality of different motion sequences is selected based on one or more parameters. An optimized inspection program configured to update operating parameters of the robot inspection system to perform the selected motion sequence and capture data using the one or more sensors is generated.

Abstract: The present application includes a rotor blade having an erosion protective coating, the coating being a cermet material configured to protect against erosion during the operation of the rotor blade. Further, the present application includes a method of selectively applying the erosion protective coating, a method of selectively repairing/reapplying the erosion protective coating, and a process of developing an erosion surface model map of an optimized erosion protective coating pattern and thickness.

Abstract: One aspect of a process to inspect a composite component includes traversing multiple ultrasonic probe array portions on respective multiple component surfaces of the composite component. The multiple component surfaces are either separate from or at angles to each other. The process includes simultaneously passing an ultrasonic signal into the multiple component surfaces through the multiple ultrasonic probe array portions. The process also includes receiving a response to the ultrasonic signal through the multiple ultrasonic probe array portions.

Abstract: A system is provided in one embodiment for real-time detection of an object in a fluid without interfering with fluid flow. The system may include a sensor element coupled to a fluid passage, which can transmit energy substantially parallel to the flow direction of a fluid in the fluid passage and receive energy reflected from an incident object in the fluid. Reflected energy can also be analyzed as a function of object size and material such that an object can be classified or characterized through appropriate signal analysis. A method is provided in another embodiment for detecting an object in a fluid passage. The method may include transmitting ultrasonic energy through an interface membrane into the fluid and receiving ultrasonic energy reflected from the object. A pressure change in the reflected ultrasonic energy may be measured and converted to a signal for an output device.

Abstract: A system and method to inspect flaws associated with a part. The system includes a first image capturing device configured to capture a first set of images of the part and a computer operably associated with first image capturing device and configured to receive and analyze the first set of images. The method includes treating the part with a magnetic particle and fluorescent penetrant processing, capturing a first set of images of an outer surface of the part with the first image capturing device, and identifying a part defect with an algorithm associated with the computer.

Abstract: A system and method to inspect flaws associated with a part. The system includes a first image capturing device configured to capture a first set of images of the part and a computer operably associated with first image capturing device and configured to receive and analyze the first set of images. The method includes treating the part with a nital etchant solution, capturing a first set of images of an outer surface of the part with the first image capturing device, and identifying a part defect with an algorithm associated with the computer.

Abstract: The present application includes a rotor blade having an erosion protective coating, the coating being a cermet material configured to protect against erosion during the operation of the rotor blade. Further, the present application includes a method of selectively applying the erosion protective coating, a method of selectively repairing/reapplying the erosion protective coating, and a process of developing an erosion surface model map of an optimized erosion protective coating pattern and thickness.

Abstract: The present application includes a rotor blade having an erosion protective coating, the coating being a cermet material configured to protect against erosion during the operation of the rotor blade. Further, the present application includes a method of selectively applying the erosion protective coating, a method of selectively repairing/reapplying the erosion protective coating, and a process of developing an erosion surface model map of an optimized erosion protective coating pattern and thickness.

Abstract: A rotor blade abrasion strip and method to manufacturing the same. The abrasion strip being composed of a molded amorphous metal contoured to match a leading edge outer surface of the rotor blade. The abrasion strip being configured to removably attach to a leading edge of the rotor blade and configured to prevent damage to the leading edge during flight. The method includes molding the abrasion strip with the amorphous metal.

Abstract: A field deployable infrared imaging (FDIR) system for inspecting a composite component comprises an emitter configured to impart heat into a composite component via infrared radiation, a camera configured to capture an infrared image of the composite component, and a processing system configured to post-process the infrared image. A method of inspecting a composite component is disclosed that comprises subjecting a component to infrared radiation, capturing a thermal image of the component, inspecting the captured thermal image for defects in the composite component, and post-processing the thermal image using a second order derivative algorithm wherein the post-processed thermal image shows the defect better than the captured infrared image.

Abstract: A system is provided in one embodiment for real-time detection of an object in a fluid without interfering with fluid flow. The system may include a sensor element coupled to a fluid passage, which can transmit energy substantially parallel to the flow direction of a fluid in the fluid passage and receive energy reflected from an incident object in the fluid. Reflected energy can also be analyzed as a function of object size and material such that an object can be classified or characterized through appropriate signal analysis. A method is provided in another embodiment for detecting an object in a fluid passage. The method may include transmitting ultrasonic energy through an interface membrane into the fluid and receiving ultrasonic energy reflected from the object. A pressure change in the reflected ultrasonic energy may be measured and converted to a signal for an output device.

Abstract: In accordance with one embodiment, a method is provided for non-destructive examination of a composite structure having a non-conductive surface and a conductive substrate. The method may include applying an alternating current to a probe having a coil conductor, scanning the probe across the non-conductive surface to induce eddy currents in the conductive substrate, and measuring changes in an electrical property of the probe in response to changes in the eddy currents indicative of variations in the depth of the conductive substrate.