Abstract: The operation of tow cutters in an automatic fiber placement machine are monitored to determine if inconsistencies in fiber placement are related to cutter operation. A machine vision system detects inconsistencies in tow placement, and timing signals are generated that represent the actuation of the cutters. The timing signals are correlated with recorded images of the placed tows to determine if the inconsistency in tow placement is related to cutter operation.

Abstract: The operation of tow cutters in an automatic fiber placement machine are monitored to determine if inconsistencies in fiber placement are related to cutter operation. A machine vision system detects inconsistencies in tow placement, and timing signals are generated that represent the actuation of the cutters. The timing signals are correlated with recorded images of the placed tows to determine if the inconsistency in tow placement are related to cutter operation.

Abstract: An apparatus may comprise a nondestructive evaluation system and a cutting system. The nondestructive evaluation system may be configured to inspect a processed portion of a structure. The nondestructive evaluation system may be configured to determine whether an inconsistency is present in the processed portion. The nondestructive evaluation system may also be configured to generate information about a location of the inconsistency. The cutting system may be configured to cut a number of parts out of the processed portion of the structure in which the inconsistency may be at least substantially excluded from the number of parts.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate, such as a metallic interleaved composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness, at least one metallic shim, and at least one mesh. A plurality of metallic shims and meshes may be disposed in alternating layers within the member. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the metallic shim may aide in modeling a metallic laminate.

Abstract: Systems and methods for determining an inconsistency characteristic of a composite structure, such as inconsistency density-per-unit area. In one implementation, a method is disclosed for determining an inconsistency characteristic of a composite structure. The method involves determining a first distance from a first reference point of the composite structure to an inconsistency; determining a second distance from a second reference point of the composite structure to the inconsistency; using the first and second distances to establish a reference area of the composite structure; and considering each inconsistency detected within the reference area and producing therefrom an inconsistency characteristic representative of the composite structure.

Abstract: Methods and systems for an armor system are provided. The system includes a first face sheet and a shaped preform extending from the first face sheet. The preform includes a first edge proximate the first face sheet, a sidewall extending from the first edge to a flange extending substantially perpendicularly from the sidewall. The preform circumscribes an area of the first face sheet. The system also includes a tile of armor material complementarily-shaped to fit within the area circumscribed by the preform. The tile is positioned within the preform such that at least a portion of the tile is between the first face sheet and the flange. The system includes a second face sheet covering the preform and the tile on a side opposite from the first face sheet.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness. The member may be defined by at least one hollow, non-spherical shaft. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The non-spherical shaft may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Abstract: A flaw and foreign object debris (FOD) detection system (11) for use during fabrication of a structure (12) includes an illumination device (13). The illumination device (13) is configured to be in proximity with a fabrication system (10) and illuminates a portion (18) of the structure (12). The illumination device (13) directs light rays (16) at acute angles relative to the portion (18). A detector (14) monitors the portion (18) and detects FOD in the portion (18) during fabrication of the structure (12) in response to the reflection of the light rays (16) off of the portion (18).

Abstract: The embodiments of the disclosure relate to a method of displaying an image of an inconsistency on a part. The part may be scanned. An inconsistency on the part may be located. An image of the inconsistency may be displayed on the part. In other embodiments, parts are provided which had images of the parts' inconsistencies displayed on one or more surfaces of the parts.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a cored composite laminate having porosity. An ultrasonic inspection reference standard for cored composite laminates having porosity may include a member having at least one thickness, at least one core, and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the core may aide in modeling a cored composite laminate. The manufactured reference standard may replace more costly porous, cored, composite laminate reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: A system and method for remote rework imaging a part for an inconsistency is provided. The part is scanned with a nondestructive inspection device. An image of a part inconsistency is communicated from the nondestructive inspection device to a programmable device. The image of the part inconsistency is viewed with the programmable device. The image of the part inconsistency is edited with the programmable device using an input device in communication with the programmable device. The edited image is communicated from the programmable device to a visible light projector. The edited image is projected onto the part inconsistency using the visible light projector.

Abstract: A flaw and foreign object debris (FOD) detection system (11) for use during fabrication of a structure (12) includes an illumination device (13). The illumination device (13) is configured to be in proximity with a fabrication system (10) and illuminates a portion (18) of the structure (12). The illumination device (13) directs light rays (16) at acute angles relative to the portion (18). A detector (14) monitors the portion (18) and detects FOD in the portion (18) during fabrication of the structure (12) in response to the reflection of the light rays (16) off of the portion (18).

Abstract: Apparatus and methods for adjustably supporting probes are disclosed. In one embodiment, a sensor support assembly includes a base member adapted to be positioned proximate to and move along a surface of a material, the base member including a first outwardly projecting engagement member and a second outwardly projecting engagement member spaced apart from the first engagement member, and a support member coupled to the base member and including a boss adapted to engage a probe, wherein the first and second engagement members are adapted to engage the surface and to maintain a stand-off distance between the probe and the surface.

Abstract: A system for determining cumulative tow gap width includes an in-process vision system having at least one camera adapted to record images of a composite material and a data analysis computer communicating with and adapted to receive image data from the in-process vision system. The data analysis computer may be adapted to calculate a cumulative gap width of tow gaps in the composite material. A user interface may communicate with and be adapted to receive data analysis results from the data analysis computer. A method for determining cumulative tow width gap of tow gaps in a composite structure is also disclosed.

Abstract: The operation of tow cutters in an automatic fiber placement machine are monitored to determine if inconsistencies in fiber placement are related to cutter operation. A machine vision system detects inconsistencies in tow placement, and timing signals are generated that represent the actuation of the cutters. The timing signals are correlated with recorded images of the placed tows to determine if the inconsistency in tow placement are related to cutter operation.

Abstract: Method and system for determining cumulative foreign object characteristics during fabrication of a composite structure. Images of sequential segments of a composite structure may be recorded during placement of the composite structure. The recorded images may be analyzed for detecting foreign objects on the composite structure. Cumulative foreign object characteristics of the foreign objects detected on the composite structure may be determined, and the cumulative foreign object characteristics may be provided to a user.

Abstract: Methods and systems for an armor system are provided. The system includes a first face sheet and a shaped preform extending from the first face sheet. The preform includes a first edge proximate the first face sheet, a sidewall extending from the first edge to a flange extending substantially perpendicularly from the sidewall. The preform circumscribes an area of the first face sheet. The system also includes a tile of armor material complementarily-shaped to fit within the area circumscribed by the preform. The tile is positioned within the preform such that at least a portion of the tile is between the first face sheet and the flange. The system includes a second face sheet covering the preform and the tile on a side opposite from the first face sheet.