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

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 a hole, crack, wrinkle, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting defect areas within the 3-D image in real time or near real time and providing data regarding each defect area, such as the depth, size, and/or type of each defect.

The invention claimed is: 
     
         1 . 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 disposed within a coupling fluid-filled chamber of a transducer housing assembly;   wherein the ultrasonic transducer is operable to emit ultrasonic waves into and receive ultrasonic waves from a test object;   wherein the ultrasonic transducer is operable to scan the test object based on a plurality of gate regions, corresponding to different depth ranges within the test object to produce scan data;   wherein the processor is operable to generate a plurality of C-scans based on the scan data, wherein each of the plurality of C-scans corresponds to one of the plurality of gate regions; and   wherein the processor is operable to automatically determine at least one angle associated with fibers identified in each of the plurality of C-scans relative to a fixed basis line.   
     
     
         2 . The system of  claim 1 , wherein the scan data is processed using a two-dimensional Fast Fourier Transform (2D FFT). 
     
     
         3 . The system of  claim 1 , wherein, based on the scan data, the processor determines whether a ply corresponding to each of the plurality of C-scans is unidirectional or weave. 
     
     
         4 . The system of  claim 1 , wherein the processor is operable to automatically determine the at least one angle associated with the fibers without the use of a calibration block. 
     
     
         5 . The system of  claim 1 , wherein the ultrasonic transducer operates at a frequency between 5 and 15 MHz. 
     
     
         6 . The system of  claim 1 , wherein the processor calculates the difference in the at least one angle associated with the fibers in each subsequent C-scan in the plurality of C-scans. 
     
     
         7 . The system of  claim 1 , wherein the test object is a composite laminate, and wherein each gate region corresponds to a range of depths approximately equal to one tenth the size of an individual lamina of the test object. 
     
     
         8 . The system of  claim 1 , wherein at least one of the plurality of C-scans corresponds to a ply including fibers with a multiplicity of orientations, and wherein the processor is operable to determine each of the multiplicity of orientations. 
     
     
         9 . 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 ultrasonic transducer is operable to scan the test object based on a plurality of gate regions, corresponding to different depth ranges within the test object to produce scan data;   wherein the processor is operable to generate a plurality of C-scans based on the scan data, wherein each of the plurality of C-scans corresponds to one of the plurality of gate regions;   wherein the processor is operable to automatically determine at least one angle associated with fibers identified in each of the plurality of C-scans relative to a fixed basis line; and   wherein the processor is operable to automatically determine the at least one angle associated with the fibers without the use of a calibration block.   
     
     
         10 . The system of  claim 9 , wherein the ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly. 
     
     
         11 . The system of  claim 9 , wherein the scan data is processed using a two-dimensional Fast Fourier Transform (2D FFT). 
     
     
         12 . The system of  claim 9 , wherein, based on the scan data, the processor determines whether a ply corresponding to each of the plurality of C-scans is unidirectional or weave. 
     
     
         13 . The system of  claim 9 , wherein the ultrasonic transducer operates at a frequency between 5 and 15 MHz. 
     
     
         14 . The system of  claim 9 , wherein the processor calculates the difference in the at least one angle associated with the fibers in each subsequent C-scan in the plurality of C-scans. 
     
     
         15 . The system of  claim 9 , wherein the test object is a composite laminate, and wherein each gate region corresponds to a range of depths approximately equal to one tenth the size of an individual lamina of the test object. 
     
     
         16 . The system of  claim 9 , wherein at least one of the plurality of C-scans corresponds to a ply including fibers with a multiplicity of orientations, and wherein the processor is operable to determine each of the multiplicity of orientations. 
     
     
         17 . 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 ultrasonic transducer is operable to scan the test object based on a plurality of gate regions, corresponding to different depth ranges within the test object to produce scan data;   wherein the processor is operable to generate a plurality of C-scans based on the scan data, wherein each of the plurality of C-scans corresponds to one of the plurality of gate regions;   wherein, based on the scan data, the processor determines whether a ply corresponding to each of the plurality of C-scans is unidirectional or weave; and   wherein the processor is operable to determine whether the ply corresponding to each of the plurality of C-scans is unidirectional or weave without the use of a calibration block.   
     
     
         18 . The system of  claim 17 , wherein the ultrasonic transducer is disposed within a coupling fluid-filled chamber of a transducer housing assembly. 
     
     
         19 . The system of  claim 17 , wherein the ultrasonic transducer operates at a frequency between 5 and 15 MHz. 
     
     
         20 . The system of  claim 17 , wherein the processor is operable to automatically determine at least one angle associated with fibers identified in each of the plurality of C-scans relative to a fixed basis line.