Abstract: A method and system of determining the physical dimensions and configuration of a structure or system as a precursor to the design of modifications of the structure or system by analyzing hidden objects within the structure or system is provided. The method includes accessing the structure or system prior to the modification for preparation of the modification; scanning the structure or system with an x-ray backscatter unit; collecting data from the x-ray backscatter unit and combining and reconstructing the data into a 2-D, 2-D panoramic or 3-D data set; producing surfaces and structures of the hidden objects from the data set; and tying the surfaces and structures of the hidden objects into a pre-existing coordinate system of the structure or system creating a 3-D model.

Abstract: A system and methods for x-ray backscatter reverse engineering of structures. One embodiment includes a plurality of articulated arms attached to a movable base. Another embodiment includes a single counterweighted arm attached to a movable base. The arms include x-ray detectors. At least one x-ray source, which may be mounted on the arm(s), emits x-rays, which are backscattered off the surfaces and objects of interest and captured by the detectors to generate images of hidden objects. The present system provides improved speed and resolution over prior art systems. The system has a field-of-view and effective scanning range versatile enough to work in various orientations and in environments of various sizes. In certain embodiments the system is compact and lightweight so that it can be easily transported and used within confined spaces or in environments where weight is a consideration, such as inside or underneath aircraft. The system is also pointable and adaptable.

Abstract: A method and apparatus for an x-ray apparatus. The x-ray apparatus comprises a vacuum tube. A cathode is located in the vacuum tube and capable of emitting electrons. A rotatable magnetic anode located in the vacuum tube, capable of being rotated by a motor located outside of the vacuum tube, and capable of generating an x-ray beam in response to receiving the electrons emitted by the cathode.

Abstract: A rapid image-based method for validating good electrical contact between existing LSP material on a structure, and LSP material on an applied patch, thus ensuring continuous LSP through the patch. The method and apparatus are used in the repair of LSP by validating an electrical connection between new and existing LSP materials. It can also be used during manufacturing to ensure good contact between sections of LSP material.

Abstract: A method and apparatus for non-destructive examination of structures. In one advantageous embodiment, an apparatus comprises a transmitter and a conformable sensor. The transmitter is capable of transmitting electromagnetic radiation through a first side of a structure. The conformable sensor is capable of detecting the electromagnetic radiation.

Abstract: A system and methods for x-ray backscatter reverse engineering of structures. One embodiment includes a plurality of articulated arms attached to a movable base. Another embodiment includes a single counterweighted arm attached to a movable base. The arms include x-ray detectors. At least one x-ray source, which may be mounted on the arm(s), emits x-rays, which are backscattered off the surfaces and objects of interest and captured by the detectors to generate images of hidden objects. The present system provides improved speed and resolution over prior art systems. The system has a field-of-view and effective scanning range versatile enough to work in various orientations and in environments of various sizes. In certain embodiments the system is compact and lightweight so that it can be easily transported and used within confined spaces or in environments where weight is a consideration, such as inside or underneath aircraft. The system is also pointable and adaptable.

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: A computer implemented method, apparatus, and computer usable program code for generating a three-dimensional model of an object of interest in an aircraft. In response to transmitting a plurality of x-rays from a set of transmission points into the aircraft, backscatter x-ray data is received. The object identified from a two-dimensional diagram of the backscatter data. Points for the object are created from the identification of the object in the received data. The points are placed at a first distance from the transmission points to form a first curve. The points are placed at a second distance from the transmission points to form a second curve. A first surface is formed from the first and second curves. A second surface is formed that intersects the first surface to form an intersection. Three-dimensional data is generated for the three-dimensional model of the object from the intersection.

Abstract: A rapid image-based method for validating good electrical contact between existing LSP material on a structure, and LSP material on an applied patch, thus ensuring continuous LSP through the patch. The method and apparatus are used in the repair of LSP by validating an electrical connection between new and existing LSP materials. It can also be used during manufacturing to ensure good contact between sections of LSP material.

Abstract: An X-ray imaging system is provided which includes an X-ray tube including, a cathode for emitting electrons; and a dynamic anode. The dynamic anode receives the electrons from the cathode and generates an X-ray beam that is non-stationary. The dynamic anode rotates between a first position where the X-ray beam is directed at a first location on an object and a second position where the X-ray beam is directed at a second location on the object to generate the non-stationary beam.

Abstract: A method and apparatus for an x-ray apparatus. The x-ray apparatus comprises a vacuum tube. A cathode is located in the vacuum tube and capable of emitting electrons. A rotatable magnetic anode located in the vacuum tube, capable of being rotated by a motor located outside of the vacuum tube, and capable of generating an x-ray beam in response to receiving the electrons emitted by the cathode.

Abstract: A system and methods for x-ray backscatter reverse engineering of structures. One embodiment includes a plurality of articulated arms attached to a movable base. Another embodiment includes a single counterweighted arm attached to a movable base. The arms include x-ray detectors. At least one x-ray source, which may be mounted on the arm(s), emits x-rays, which are backscattered off the surfaces and objects of interest and captured by the detectors to generate images of hidden objects. The present system provides improved speed and resolution over prior art systems. The system has a field-of-view and effective scanning range versatile enough to work in various orientations and in environments of various sizes. In certain embodiments the system is compact and lightweight so that it can be easily transported and used within confined spaces or in environments where weight is a consideration, such as inside or underneath aircraft. The system is also pointable and adaptable.

Abstract: Methods and systems are disclosed for drilling counter sink fastener holes in composite materials with conductive foil lightning strike protection systems. Initially a non-destructive depth detector is scanned over a prospective fastener hole location. Then the depth of a conductive foil below a surface is detected. When the detected depth is less than a predetermined depth, a signal that indicates that a countersink fastener hole may be drilled is output. When the detected depth is greater than a predetermined depth, a signal that indicates that a countersink fastener hole may not be drilled is output.

Abstract: Exemplary systems and methods are provided for imaging a unit under test. Orientation of an imaging system is determined with a machine vision system, a unit under test is scanned with the imaging system, and the scanned image is processed into a substantially distortion-free image. The scanned image may be processed into a substantially distortion-free image by mapping a scanned image to coordinates determined by the machine vision system. By combining the position and orientation information collected at the time each image pixel is collected, the image can be assembled without distortion by mapping a detector signal to the appropriate image coordinate. Alternately, the scanned image may be processed into a substantially distortion-free image by mapping a scanned image to a predetermined matrix grid of coordinates, identifying distortion in the scanned image, and correcting identified distortion in the scanned image.

Abstract: A method, apparatus, and computer usable program code for non-destructive detection of corrosion using quantum dots. In one embodiment, a surface of an area on a commodity associated with a set of quantum dots is tested. A pattern of wavelengths emitted by the set of quantum dots associated with the surface of the commodity is detected to form a quantum dot pattern. The quantum dot pattern is analyzed to determine whether corrosion has occurred in the area on the surface of the commodity.

Abstract: Nondestructive examination is performed on a composite aircraft component including a composite body and a conductive medium. The conductive medium is substantially more conductive than the composite body. The nondestructive examination includes applying an electromagnetic field that penetrates the composite body and heats the conductive medium, and creating a thermal image of the conductive medium to reveal conductivity information about the conductive medium.

Abstract: A method and system for identifying foreign objection (FOD) in items such as aircraft are disclosed. The item may be imaged using x-ray backscatter before and after work is performed thereon. The image taken before work may be subtracted from the image taken after the work to provide a resultant image. The resultant image may indicate the presence of any FOD. Potential FOD in the resultant image may be checked against a database of known FOD to determine the identity thereof. By finding FOD, the occurrence of catastrophes such as aircraft crashes may be mitigated.

Abstract: Optical metrology methods, apparatuses, and systems for detecting seal integrity. These comprise changing an air pressure inside a chamber to an excitation pressure level when the chamber is placed over a segment of a surface of a structure having one or more seal features and determining whether the integrity of any of the one or more seal features has been compromised by determining, using an optical system, whether any of the one or more seal features have been deformed by the changing of the air pressure.

Abstract: A self-aligning probe assembly has one or more ultrasonic transducers adapted to transmit an ultrasonic shear wave into the inside surface of the hollow structure such as an aircraft fuse pin and to receive the shear wave emerging from the inside surface of the hollow structure. The nature of the received shear wave indicates the presence of flaws or damage in the inspected part. The probe assembly can be used to inspect fuse pins on aircraft without having to remove the aircraft engines.

Abstract: A low-profile real-time x-ray detector has a visual sensor that provides a wide angle visual image of a location on an inspected part that is being x-rayed. Fish eye lenses in the visual sensor view a reflection of a part being inspected from a highly reflective surface mirror on an x-ray sensitive surface. The visual sensor may provide an exact visual replica of the area on the inspected part that is being x-rayed.