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Scalable NDT Instruments for the Inspection of Variable Geometry Components
The document discusses Olympus NDT Canada's adaptive phased array (APA) solution for inspecting complex geometry components in the aviation industry. It outlines the evolution of non-destructive testing (NDT) technologies, addressing challenges such as complex geometry and the need for skilled operators, while highlighting the benefits of APA for faster and more reliable inspections. Results from various cases demonstrate improved detection rates and defect size measurement when using the APA compared to traditional methods.
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Scalable NDT Instruments for the Inspection of Variable Geometry Components
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- 2. Agenda 1. Introduc<on and evolu<on of NDE in the avia<on industry OLYMPUS ScientificSolutions 2. Complex geometry inspec<on challenges 3. Goals 4. Solu<on : Adap<ve phased array • Design introduc$on & overview • Results 5. Conclusion & next steps
- 3. OLYMPUS Scientific Solutions Introduc<on § Ultrasonic (UT) technology & instruments have been used in a wide variaty of industries for NDE over the last 20 years § Introduction of carbon laminates composite, in conjuction with recent low oil prices helped airline companies to save money, explaining above normal growth
- 4. OLYMPUS Scientific Solutions Introduc<on § Consequently, aviation components manufacturers are facing new challenges: § Rise in production rate § Increasingly complex geometry § Lack of skilled operators § More demanding inspection requirements
- 5. OLYMPUS Scientific Solutions Introduc<on § Evolution of PA instruments help address these challenges § Scalable PA instruments provide the following benefits § Faster inspection § Improved coverage for better repeatability § Improved radius inspection High pulsing frequency PRF Up to 20 kHz High data transfer rate Data Throughput Up to 30 MB/s
- 6. OLYMPUS Scientific Solutions Introduc<on § Some challenges remain when full volumetric inspection of varying geometry (varying, flatten radius, tilted parts) is required. § Today, these parts are either inspected manually or via complex mechanical devices that are error- prone, hard to configure, and costly
- 7. OLYMPUS Scientific Solutions Challenges § Inspection of carbon laminate parts with the following characteristics: § Variable radius § Variable opening angle § Twisted § Inspection of non-constant (weighted) radius generated by the manufacturing process § Inspection of rounded flat surfaces generated by the inspection process § Part vs probe alignment (curved and flat arrays)
- 8. OLYMPUS Scientific Solutions Goals § Improve & simplify the inspection of complex geometry components § Variable & weighted radius § Variable opening and twisted parts § Flexible solution to enable inspection from: § Inside & outside radius § Flat surface § Efficient solution § Inspection speed has to be similar to what is achieve today with standard phased array § Reliable & robust solution
- 9. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Introduc<on 0dB -3dB -6dB BeamWidth Delay PAprobe Wave front Part PA probe Delay Part Wave front § What is the most desirable configuration?
- 10. Adap<ve PA Solu<on Introduc<on Delay PA probe Wave front Part PAprobe Delay Part Wave front § What is the most desirable configuration? FW BW ? FW BW 0dB -3dB -6dB BeamWidth
- 11. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Introduc<on Delay 0dB -3dB -6dB BeamWidth PAprobe Wave front Part FW BW ? 0dB -3dB -6dB BeamWidth PA probe Delay Part Wave front FW BW § Adaptive phased array is an iterative process that enables the transmission of a wave-front parallel to the part n iterations
- 12. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Design DelayBank Pulser Nb. Delay Delay Bank Pulser Nb. Delay L1 0 L2 0 …………………………………….......... Ln 0
- 13. 0dB -3dB -6dB BeamWidth PA probe (Rx) Part BW? OLYMPUS Scientific Solutions Adap<ve PA Solu<on Design 0dB -3dB -6dB BeamWidth PA probe (Tx) Wave front Part BW ? Wave front
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- 15. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Design Isthe frontwall corrected within a predefined tolerance (δ ) ? +δ - δ +δ - δ
- 16. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Design Delay Part Wavefront 0dB -3dB -6dB BeamWidth
- 17. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Simulation Configuration First iteration Last iteration
- 18. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 1: Varying radius § Part & scan parameters § Geometry: L shape § Radius : 5 mm to 10 mm § Scan : External face § Probe : 5CC25-32R4 § Wedge : SR4-IE90
- 19. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 1: Varying radius § Results § Detection § 2830 with APA § 2030 without APA § Defect Size § 77 mm2 with APA § 66 mm2 without APA § SNR § 23 dB with APA § 9 dB without APA Figure 1 : Amplitude C-scan with APA Figure 2 : Position C-scan with APA Figure 3 : Amplitude C-scan without APA Figure 4 : Position C-scan without APA
- 20. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 2: Varying radius § Part & scan parameters § Geometry: L shape § Radius : 5mm to 10mm § Scan : Internal face § Probe : 5CC25-32R4 § Wedge : SR4-IE90
- 21. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 2: Varying radius § Results § Detection § 2630 with APA § 1830 without APA § Defect Size (area in mm) § 91 mm2 with APA § 84 mm2 without APA § SNR § 22 dB with APA § 22 dB without APA Figure 1 : Amplitude C-scan with APA Figure 2 : Position C-scan with APA Figure 3 : Amplitude C-scan without APA Figure 4 : Position C-scan without APA
- 22. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 3: Varying & weighted radius § Part & scan parameters § Geometry: L shape § Radius: 5 mm to 10 mm § Weighted: 10 mm § Scan: Internal face § Probe: 5CC25-32R4 § Wedge: SR4-IE90
- 23. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Case 3: Varying & weighted radius § Results § Detection § 2630 with APA § 1330 without APA § Defect Size (area in mm) § 90 mm2 with APA § 88 mm2 without APA § SNR § 12 dB with APA § 0 dB without APA Figure 1 : Amplitude C-scan with APA Figure 2 : Position C-scan with APA Figure 3 : Amplitude C-scan without APA Figure 4 : Position C-scan without APA
- 24. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Productivity Parameters Number of elements 32 Aperture size 4 Aperture steps 1 Water path 25 mm Material thickness 8.5 mm Material velocity 2700 ms Number of iterations 5 PRF with APA PRF without APA 300 Hz 517 Hz
- 25. OLYMPUS Scientific Solutions Adap<ve PA Solu<on Results § Reliability and ruggedness
- 26. OLYMPUS Scientific Solutions Conclusion § Improve & simplify the inspection of complex geometry components § Variable & weighted radius § Variable opening and twisted parts § Flexible solution enabling inspection from § Inside & outside radius § Flat surface § Efficient solution § Inspection speed has to be similar to what is acheive today with standard phased array § Reliable & robust solution
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- 28. OLYMPUS Scientific Solutions Conclusion and next steps Figure1 : With first generation APA Figure 2 : With second generation APA
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