System and method for real-time visualization of defects in a material

Patent metadata

Field	Value
Publication number	US-12146859-B2
Application number	US-202318232106-A
Country	US
Kind code	B2
Filing date	Aug 9, 2023
Priority date	Mar 30, 2020
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system includes a graphical user interface (GUI) capable of showing a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. The GUI is capable of displaying the 3-D image as each additional 2-D cross section is scanned by an ultrasonic testing apparatus in real time or near real time, including probable defect regions that contain a flaw such as an air pocket, delamination, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting foreign objects within the 3-D image in real time or near real time and providing data regarding each object area, such as the depth, size, and/or type of each defect.

First claim

The invention claimed is:

1. A system for non-destructive testing of composite materials, comprising:
a transducer housing assembly in communication with a processor and a display means;
wherein an ultrasonic transducer is disposed within a sealed fluid chamber within the transducer housing assembly;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object;
wherein the test object includes a layered composite material;
wherein the ultrasonic transducer is a spherically focused ultrasonic transducer;
wherein the processor generates an area and a characteristic length of a foreign object within the test object;
wherein the processor is in communication with a material database containing information regarding a plurality of materials, and wherein the processor matches a material of the foreign object to at least one of the plurality of materials; and
wherein the processor generates a list including the at least one of the plurality of materials, wherein the processor automatically assigns and displays a probability value corresponding to a likelihood that each material in the list matches the material of the foreign object.

2. The system of claim 1 , wherein the characteristic length of the foreign object is less than 6 mm.

3. The system of claim 1 , wherein the generated characteristic length for the foreign object differs from a true characteristic length of the foreign object by less than 0.5 mm.

4. The system of claim 1 , wherein the information regarding the plurality of materials includes the speed of sound in each of the plurality of materials and/or a density of each of the plurality of materials.

5. The system of claim 1 , wherein the ultrasonic transducer operates at a frequency greater than 2.25 MHz.

6. The system of claim 1 , wherein the test object includes a plurality of layers, and wherein the processor is operable to provide information including a depth of the foreign object from a testing surface and which layers of the plurality of layers the foreign object extends through.

7. The system of claim 1 , wherein a plurality of A-scans is generated for a plurality of depths of the test object, and wherein boundaries of the foreign object at each of the plurality of depths are determined by mapping a gradient of amplitudes of the plurality of A-scans at each of the plurality of depths.

8. The system of claim 1 , wherein the processor generates a three-dimensional (3-D) graphical representation of the test object, including the foreign object, and the 3-D graphical representation is displayed via the display means.

9. The system of claim 8 , wherein an artificial intelligence module automatically highlights the foreign object on the 3-D graphical representation.

10. The system of claim 1 , wherein the test object includes a plurality of layers, and wherein nine or more layers of the test object are between the transducer and the foreign object.

11. A system for non-destructive testing of composite materials, comprising:
a transducer housing assembly, including an ultrasonic transducer, in communication with a processor and a display means;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object;
wherein the processor generates an area and a characteristic length of a foreign object within the test object;
wherein the processor generates a three-dimensional (3-D) graphical representation of the test object, including the foreign object, and the 3-D graphical representation is displayed via the display means;
wherein the processor is in communication with a material database containing information regarding a plurality of materials, and wherein the processor matches a material of the foreign object to at least one of the plurality of materials; and
wherein the processor generates a list including the at least one of the plurality of materials, wherein the processor automatically assigns and displays a probability value corresponding to a likelihood that each material in the list matches the material of the foreign object.

12. The system of claim 11 , wherein an artificial intelligence module automatically highlights the foreign object on the 3-D graphical representation.

13. The system of claim 11 , wherein an ultrasonic transducer is disposed within a sealed fluid chamber within the transducer housing assembly.

14. The system of claim 11 , wherein the information regarding the plurality of materials includes the speed of sound in each of the plurality of materials and/or a density of each of the plurality of materials.

15. The system of claim 11 , wherein the ultrasonic transducer operates at a frequency greater than 2.25 MHz.

16. The system of claim 11 , wherein a plurality of A-scans is generated for a plurality of depths of the test object, and wherein boundaries of the foreign object at each of the plurality of depths are determined by mapping a gradient of amplitudes of the plurality of A-scans at each of the plurality of depths.

17. The system of claim 11 , wherein the characteristic length of the foreign object is less than 6 mm.

18. The system of claim 11 , wherein the generated characteristic length for the foreign object differs from a true characteristic length of the foreign object by less than 0.5 mm.

19. A system for non-destructive testing of composite materials, comprising:
an ultrasonic transducer in communication with a processor and a display means;
wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object;
wherein the test object includes a layered composite material;
wherein the processor generates an area and a characteristic length of a foreign object within the test object;
wherein a plurality of A-scans is generated for a plurality of depths of the test object, and wherein boundaries of the foreign object at each of the plurality of depths are determined by mapping a gradient of amplitudes of the plurality of A-scans at each of the plurality of depths;
wherein the processor is in communication with a material database containing information regarding a plurality of materials, and wherein the processor matches a material of the foreign object to at least one of the plurality of materials; and
wherein the processor generates a list including the at least one of the plurality of materials, wherein the processor automatically assigns and displays a probability value corresponding to a likelihood that each material in the list matches the material of the foreign object.

20. The system of claim 19 , wherein the characteristic length of the foreign object is less than 6 mm.

Assignees

• Verifi Tech Llc
• Univ Baylor

Inventors

• Jack David A
• Blandford Benjamin M
• Blackman Nathaniel J

Classifications

• G01N29/0645

  Display representation or displayed parameters, e.g. A-, B- or C-Scan · CPC title

• G01N29/4445

  Classification of defects · CPC title

• G01N2291/101

  one transducer · CPC title

• G01N29/348

  with frequency characteristics, e.g. single frequency signals, chirp signals (measuring frequency of mechanical vibrations or acoustic waves in general G01H1/06, G01H3/04; measuring frequency or analysing frequency spectra G01R23/00) · CPC title

• G01N29/11

  by measuring attenuation of acoustic waves · CPC title