Abstract: Disclosed herein is an ultrasonic inspection probe for inspecting parts. The ultrasonic inspection probe comprises a probe body that comprises an ultrasonic array and a plate attachment surface. The ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface. The ultrasonic inspection probe also comprises an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, and a part inspection surface, shaped to complement a shape of one of the parts.

Abstract: A method for testing a structure includes steps of: identifying a three-dimensional position of a surface of the structure relative to a reference frame; transmitting laser light from an output of a transmitter onto the surface of the structure to form ultrasonic waves in the structure and to detect a response to the ultrasonic waves; based on the three-dimensional position of the surface, moving the laser light over the structure along a scan path so that the output of the transmitter is located at a constant offset distance from the surface and that the laser light, transmitted from the output of the transmitter, is directed onto the surface at a constant angle of projection; and based on the response to the ultrasonic waves, determining whether an inconsistency is present in the structure.

Abstract: An ultrasonic inspection device for inspection of a structure. The device includes a body with a first side and a second side that are on opposing sides of a gap. The gap is sized to receive the structure. A probe is attached to the first side and transmits ultrasonic signals at the structure. A reflector plate is attached to the second side and is fixed relative to the probe and reflects the signals that pass through the structure. The probe is configured to detect the signals that reflect off the structure and to detect the signals that pass through the structure and reflect off the reflector plate. The received signals provide for pulse echo and through transmission inspection of the structure.

Abstract: Described herein is an apparatus, for shielding light generated by a laser during non-destructive inspection of an object. The apparatus includes a light shield at least partially enveloping the laser and defining a first opening through which light generated by the laser passes from the laser to the object. The light shield is opaque and includes at least one first biasing mechanism. The apparatus also includes at least one first light seal coupled to the light shield about the first opening of the light shield. The at least one first biasing mechanism is configured to urge resilient deformation of the at least one first light seal against the object. When the at least one first light seal is resiliently deformed against the object, light generated by the laser is constrained within a light containment space defined between the light shield, the at least one first light seal, and the object.

Abstract: Disclosed herein is an ultrasonic inspection probe for inspecting parts. The ultrasonic inspection probe comprises a probe body that comprises an ultrasonic array and a plate attachment surface. The ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface. The ultrasonic inspection probe also comprises an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, and a part inspection surface, shaped to complement a shape of one of the parts.

Abstract: An ultrasonic inspection device for inspection of a structure. The device includes a body with a first side and a second side that are on opposing sides of a gap. The gap is sized to receive the structure. A probe is attached to the first side and transmits ultrasonic signals at the structure. A reflector plate is attached to the second side and is fixed relative to the probe and reflects the signals that pass through the structure. The probe is configured to detect the signals that reflect off the structure and to detect the signals that pass through the structure and reflect off the reflector plate. The received signals provide for pulse echo and through transmission inspection of the structure.

Abstract: A method for testing a structure includes steps of: identifying a three-dimensional position of a surface of the structure relative to a reference frame; transmitting laser light from an output of a transmitter onto the surface of the structure to form ultrasonic waves in the structure and to detect a response to the ultrasonic waves; based on the three-dimensional position of the surface, moving the laser light over the structure along a scan path so that the output of the transmitter is located at a constant offset distance from the surface and that the laser light, transmitted from the output of the transmitter, is directed onto the surface at a constant angle of projection; and based on the response to the ultrasonic waves, determining whether an inconsistency is present in the structure.

Abstract: Described herein is an apparatus, for shielding light generated by a laser during non-destructive inspection of an object. The apparatus includes a light shield at least partially enveloping the laser and defining a first opening through which light generated by the laser passes from the laser to the object. The light shield is opaque and includes at least one first biasing mechanism. The apparatus also includes at least one first light seal coupled to the light shield about the first opening of the light shield. The at least one first biasing mechanism is configured to urge resilient deformation of the at least one first light seal against the object. When the at least one first light seal is resiliently deformed against the object, light generated by the laser is constrained within a light containment space defined between the light shield, the at least one first light seal, and the object.

Abstract: An apparatus for removing a gas in an immersion ultrasonic process is provided. The apparatus, in the form of an immersion ultrasonic transducer holder apparatus, has a body with a first end, a second end, a plurality of sides, and a hollow interior cavity portion. A holder portion with an exterior end and an interior end is formed through the first end, and holds one or more immersion ultrasonic transducers. A sloped inner face having a base end with a knife-edged perimeter is adjacent the interior end of the holder portion. The sloped inner face has an upward sloped surface extending from the base end to an evacuation end. One or more evacuation ports are formed through the first end, and adjacent the evacuation end. When the apparatus is used in the immersion ultrasonic process, the knife-edged perimeter, sloped inner face, and evacuation ports facilitate removal of the gas.

Abstract: Described herein is an apparatus, for shielding light generated by a laser during non-destructive inspection of an object. The apparatus includes a light shield at least partially enveloping the laser and defining a first opening through which light generated by the laser passes from the laser to the object. The light shield is opaque and includes at least one first biasing mechanism. The apparatus also includes at least one first light seal coupled to the light shield about the first opening of the light shield. The at least one first biasing mechanism is configured to urge resilient deformation of the at least one first light seal against the object. When the at least one first light seal is resiliently deformed against the object, light generated by the laser is constrained within a light containment space defined between the light shield, the at least one first light seal, and the object.

Abstract: An apparatus for removing a gas in an immersion ultrasonic process is provided. The apparatus, in the form of an immersion ultrasonic transducer holder apparatus, has a body with a first end, a second end, a plurality of sides, and a hollow interior cavity portion. A holder portion with an exterior end and an interior end is formed through the first end, and holds one or more immersion ultrasonic transducers. A sloped inner face having a base end with a knife-edged perimeter is adjacent the interior end of the holder portion. The sloped inner face has an upward sloped surface extending from the base end to an evacuation end. One or more evacuation ports are formed through the first end, and adjacent the evacuation end. When the apparatus is used in the immersion ultrasonic process, the knife-edged perimeter, sloped inner face, and evacuation ports facilitate removal of the gas.

Abstract: Described herein is an apparatus, for shielding light generated by a laser during non-destructive inspection of an object. The apparatus includes a light shield at least partially enveloping the laser and defining a first opening through which light generated by the laser passes from the laser to the object. The light shield is opaque and includes at least one first biasing mechanism. The apparatus also includes at least one first light seal coupled to the light shield about the first opening of the light shield. The at least one first biasing mechanism is configured to urge resilient deformation of the at least one first light seal against the object. When the at least one first light seal is resiliently deformed against the object, light generated by the laser is constrained within a light containment space defined between the light shield, the at least one first light seal, and the object.

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 computer-controlled robotic platform with a collapsible lifting arm that positions a non-destructive inspection (NDI) sensor for scanning inside tunnel regions of a composite structure such as an integrally stiffened wing box. The lifting arm of a modified scissor lift mechanism can be collapsed to a very low height to pass through narrow sections of the integrally stiffened wing box, and also extended by more than a factor of three to reach the maximum height of the wing box tunnels. The system performs a vertical position sensing and control process that uses inverse kinematics to enable position control using data from a standard rotational encoder on the motor to determine vertical position. The system produces simulated encoder pulses that represent unit vertical displacements of a distal portion of a modified scissor lift mechanism using a forward kinematics equation in which the rotation angle of a lead screw is an input variable.

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 computer-controlled robotic platform with a collapsible lifting arm that positions a non-destructive inspection (NDI) sensor for scanning inside tunnel regions of a composite structure such as an integrally stiffened wing box. The lifting arm of a modified scissor lift mechanism can be collapsed to a very low height to pass through narrow sections of the integrally stiffened wing box, and also extended by more than a factor of three to reach the maximum height of the wing box tunnels. The system performs a vertical position sensing and control process that uses inverse kinematics to enable position control using data from a standard rotational encoder on the motor to determine vertical position. The system produces simulated encoder pulses that represent unit vertical displacements of a distal portion of a modified scissor lift mechanism using a forward kinematics equation in which the rotation angle of a lead screw is an input variable.

Abstract: Improved apparatus, systems, and methods for inspecting a structure are provided that use a probe having two ultrasonic transducer arrays. This enables simultaneous testing using two different test frequencies. The probe uses pulse echo ultrasonic signals at different frequencies to inspect the structure. The probe includes a support body having a fluid conduit formed therein. The fluid conduit provides flow paths for a couplant (such as water) that is used to couple the ultrasonic signals between the structure under test and the arrays. The fluid conduit is configured to quickly eject couplant and bubbles contained in the couplant.