Abstract: An inspection system for detecting one or more misaligned seals is disclosed and includes a linear transducer array connected to a sleeve. The linear transducer array includes a plurality of ultrasonic transducers each configured to transmit and receive ultrasonic waves. The ultrasonic transducers direct the ultrasonic waves towards one or more seals that are disposed underneath the sleeve. The inspection system also includes a rotational device configured to move the ultrasonic transducers around a circumference of the sleeve, one or more processors in electronic communication with the linear transducer array, and a memory coupled to the one or more processors. The memory stores data into a database and program code that, when executed by the one or more processors, causes the inspection system to instruct the plurality of ultrasonic transducers to transmit and receive the ultrasonic waves.

Abstract: An inspection system for detecting one or more misaligned seals is disclosed and includes a linear transducer array connected to a sleeve. The linear transducer array includes a plurality of ultrasonic transducers each configured to transmit and receive ultrasonic waves. The ultrasonic transducers direct the ultrasonic waves towards one or more seals that are disposed underneath the sleeve. The inspection system also includes a rotational device configured to move the ultrasonic transducers around a circumference of the sleeve, one or more processors in electronic communication with the linear transducer array, and a memory coupled to the one or more processors. The memory stores data into a database and program code that, when executed by the one or more processors, causes the inspection system to instruct the plurality of ultrasonic transducers to transmit and receive the ultrasonic waves.

Abstract: There is provided a system for using eddy current edge effect to measure a gap between two conductive parts. The system includes the two conductive parts, each having predetermined properties. The system includes a probe having a housing with a coil, and includes a reference gap standard, based on one or more reference gap measurements taken between at least two reference conductive parts separated by a gap distance, as specified by predetermined engineering requirements. The system includes an inspection instrument assembly coupled to the probe and having an inspection apparatus calibrated to the probe and the reference gap standard. The probe with the coil uses the eddy current edge effect to take the gap measurement and measure the gap. The gap measurement is compared to the reference gap standard, to determine whether the gap measurement is an acceptable result or an unacceptable result, based on the predetermined engineering requirements.

Abstract: There is provided a system for using eddy current edge effect to measure a gap between two conductive parts. The system includes the two conductive parts, each having predetermined properties. The system includes a probe having a housing with a coil, and includes a reference gap standard, based on one or more reference gap measurements taken between at least two reference conductive parts separated by a gap distance, as specified by predetermined engineering requirements. The system includes an inspection instrument assembly coupled to the probe and having an inspection apparatus calibrated to the probe and the reference gap standard. The probe with the coil uses the eddy current edge effect to take the gap measurement and measure the gap. The gap measurement is compared to the reference gap standard, to determine whether the gap measurement is an acceptable result or an unacceptable result, based on the predetermined engineering requirements.

Abstract: An apparatus for fabricating a stack of adhesive plies for attaching a doubler to a surface on a structure includes a digital scanner, configured for scanning the surface and for producing a first set of digital data representing a contour of the surface, and a computer, coupled to the digital scanner, having a processor and system memory. The computer is programmed for mapping a gap between a bonding surface on the doubler and the surface on the structure using the first set of digital data and a second set of digital data representing the bonding surface, and for segmenting the mapped gap into layers corresponding to the adhesive plies.

Abstract: An automated blade crawler capable of scanning a multiplicity of non-destructive inspection sensors over a surface of an airfoil-shaped body such as a blade component. The blade crawler is movable in a spanwise direction, thereby enabling a sensor array to inspect the surface area on one or both sides of the blade component in one pass. The sensors concurrently output scan imaging data which is multiplexed, the multiplexed being transmitted (via an electrical cable or wirelessly) to data collection and display hardware at an operations control center.

Abstract: A method and apparatus for evaluating an object having a wrinkle. Energy is sent into the object at a plurality of locations using an array of transmitting elements. Reflected energy is received at an array of receiving elements in response to a portion of the energy being reflected off a plurality of layers in the object. A three-dimensional model of the wrinkle in the object is created based on the reflected energy received at the array of receiving elements.

Abstract: A mechanism for adjusting the orientation of an end effector (e.g., a non-destructive inspection sensor) during movement over a contoured surface, comprising: (1) a pneumatic or spring-loaded plunger shaft that facilitates positioning of an end effector onto a highly contoured surface by allowing a wide range of vertical motion; (2) a rocker pivotably coupled to a distal end of the plunger shaft, the rocker being pivotable about a horizontal axis to allow a pair of follower wheels coupled to distal ends of the rocker arms to follow the contoured surface and keep the end effector oriented correctly relative to the surface without tipping over; and (3) a hozzle (i.e., an end effector holder) attached to the rocker for rotation therewith, the end effector being coupled to the hozzle by an elastomeric gasket or a plurality of springs which allow the orientation of the end effector relative to the hozzle to change in response to contact forces.

Abstract: An apparatus for fabricating a stack of adhesive plies for attaching a doubler to a surface on a structure includes a digital scanner, configured for scanning the surface and for producing a first set of digital data representing a contour of the surface, and a computer, coupled to the digital scanner, having a processor and system memory. The computer is programmed for mapping a gap between a bonding surface on the doubler and the surface on the structure using the first set of digital data and a second set of digital data representing the bonding surface, and for segmenting the mapped gap into layers corresponding to the adhesive plies.

Abstract: A method and apparatus are used to fit a metallic or composite doubler on an uneven surface. A three dimensional digital map of the gap between the doubler and the uneven surface is generated by digitally scanning the uneven surface. The digital map is then used to fabricate a stack of adhesive plies tailored to substantially fill the gap between the doubler and the uneven surface.

Abstract: An aircraft includes a composite structure and a plurality of small lightweight pollable communication devices for providing lightning strike detection coverage of a region of the structure. Each device is rendered inoperative if at least proximate to lightning current.

Abstract: An automated blade crawler capable of scanning a multiplicity of non-destructive inspection sensors over a surface of an airfoil-shaped body such as a blade component. The blade crawler is movable in a spanwise direction, thereby enabling a sensor array to inspect the surface area on one or both sides of the blade component in one pass. The sensors concurrently output scan imaging data which is multiplexed, the multiplexed being transmitted (via an electrical cable or wirelessly) to data collection and display hardware at an operations control center.

Abstract: A mechanism for adjusting the orientation of an end effector (e.g., a non-destructive inspection sensor) during movement over a contoured surface, comprising: (1) a pneumatic or spring-loaded plunger shaft that facilitates positioning of an end effector onto a highly contoured surface by allowing a wide range of vertical motion; (2) a rocker pivotably coupled to a distal end of the plunger shaft, the rocker being pivotable about a horizontal axis to allow a pair of follower wheels coupled to distal ends of the rocker arms to follow the contoured surface and keep the end effector oriented correctly relative to the surface without tipping over; and (3) a hozzle (i.e., an end effector holder) attached to the rocker for rotation therewith, the end effector being coupled to the hozzle by an elastomeric gasket or a plurality of springs which allow the orientation of the end effector relative to the hozzle to change in response to contact forces.

Abstract: Methods and systems are provided for measuring a thickness of an object. A first portion of a device is positioned on a first side of the object, and a second portion of the device is positioned on an opposite side of the object. The first portion includes at least one first mount and at least one eddy current sensor coupled to the first mount. The second portion includes at least one second mount and at least one target coupled to the second mount. The first mount is magnetically coupled to the second mount such that the eddy current sensor is oriented to interact with the target to enable the thickness of the object to be measured.

Abstract: A non-conductive composite doubler is fabricated for application to an electrically conductive surface of a structure by: forming the composite doubler; placing an array of capacitive gap thickness sensors between the doubler and the structure surface; measuring the gap thickness between the doubler and the structure surface in a plurality of areas over the surface of the structure; using the gap thickness measurements to shape a layer of adhesive to essentially match the contour of the structure surface; and, applying the layer of adhesive to the doubler.

Abstract: In a particular system for monitoring of a composite workpiece, at least one ultrasonic testing transducer is mounted to a surface of the composite workpiece and configured to transmit and receive ultrasonic energy to and from the composite workpiece during mechanical loading of the composite workpiece. An ultrasonic pulser/receiver is operatively coupled to the at least one ultrasonic testing transducer. A computing system is operatively coupled to the ultrasonic pulser/receiver. The computing system includes a data acquisition component configured to acquire data from the ultrasonic puller/receiver and a data analysis component configured to analyze the acquired data. The data analysis component may be further configured to analyze the acquired data for initiation of failure of the composite workpiece and/or growth of failure of the composite workpiece. Further, failure of the composite workpiece may include cracking and/or delaminating and/or disbonding.

Abstract: An ultrasonic inspection apparatus may include a chamber partly filled with water from a first portion of the chamber to a water-line disposed apart from a second portion of the chamber, and at least one transducer disposed apart from the water-line. The at least one transducer may emit ultrasonic signals through a portion of a part being inspected towards the water-line. The water-line may reflect the ultrasonic signals emitted from the at least one transducer off the water-line, back through a portion of a part being inspected, and back to the at least one transducer. In such manner, one or more portions of a complex-shaped part may be inspected.

Abstract: In non-limiting, exemplary embodiments a mount assembly is provided for mounting an inspection sensor to a surface of a workpiece. The mount assembly includes a mount having an attachment portion and an engagement portion. The attachment portion is arranged to attach the mount to the surface of the workpiece. The engagement portion is arranged to engage the inspection sensor with the mount. Exemplary mount assemblies may be arranged to mount pulse echo ultrasonic testing transducers, focused ultrasonic testing transducers, through transmission ultrasonic testing transducers, eddy current inspection sensors, or any type of inspection sensor as desired.

Abstract: An apparatus for holding an aerospace structure, having an edge and a surface, includes a base. Coupled to the base is an edge support adapted to releasably engage the edge of the structure. Also coupled to the base is a stanchion. Moveably coupled to the stanchion is a surface support adapted to support the surface of the structure when the edge of the structure is retained by the edge support.

Abstract: In a particular system for monitoring of a composite workpiece, at least one ultrasonic testing transducer is mounted to a surface of the composite workpiece and configured to transmit and receive ultrasonic energy to and from the composite workpiece during mechanical loading of the composite workpiece. An ultrasonic pulser/receiver is operatively coupled to the at least one ultrasonic testing transducer. A computing system is operatively coupled to the ultrasonic pulser/receiver. The computing system includes a data acquisition component configured to acquire data from the ultrasonic puller/receiver and a data analysis component configured to analyze the acquired data. The data analysis component may be further configured to analyze the acquired data for initiation of failure of the composite workpiece and/or growth of failure of the composite workpiece. Further, failure of the composite workpiece may include cracking and/or delaminating and/or disbonding.