Increased demands in performance and production rates require a radical new approach to the design and manufacturing of aircraft wings. Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. The geometric assessment of the parts is carried out with a robotised dynamic laser scanner encoded through an absolute laser tracker. This method allows scanning speeds up to 330mm/s at 1mm pitch. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6 GB/s. The robotic inspection system presented herein is currently being tested for industrial exploitation. The adopted system integration strategies allow traditional ultrasonic phased array scanning as well as full matrix capture (FMC) and other novel scanning approaches (e.g. multi-Tx phased array). Scan results, relative to a 1.2m x 3m carbon fibre sample, are presented. The system shows a reference scanning rate of 25.3m 2 /hour with an 8Tx/8Rx PA approach and an ultrasonically reachable scanning rate over 100m 2 /hour with the novel techniques.
Human arterial segments with occlusive defects and acute dog hearts were exposed, in vitro, to high-energy pulsed and continuous wave (CW) laser beams at argon (514 nm) and Nd-YAG (1,064 nm) wavelengths, using various pulse powers, durations and pulse repetition rates. The laser effects included vaporization of plaques in the arterial segments and penetration of the pericardial sac, evaporation of pericardial fluid, and discoloration of tissue with crater-like lesions in the impact zone, all as a result of vaporization of heart muscle tissues. The areas affected and depth of penetration depended on the wavelength, power, pulse duration, and mode of energy deposition. Focused nanosecond Nd-YAG laser pulses at repetition rates of 40-50 Hz caused ablation or vaporization of hard plaques and kidney stones in air and saline. Picosecond (mode-locked) argon laser pulses at repetition rates of 3.8 MHz--average power 6.5 W, peak power of 230 W--caused effective vaporization of hard plaques and kidney stones in air and saline. Picosecond argon laser pulses--average power 1 W, peak power 250 W--were not effective in vaporization. Transmission characteristics of the various types of laser pulses through fiber optic waveguides were determined. The energy and power density required to vaporize fatty and hard plaques and kidney stones were tabulated as a function of laser wavelength, pulse energy, duration, and repetition rates.
Ultrasound undergoes refraction and reflection at interfaces between media of different acoustic refractive indices. The most common ultrasonic method (pulse-echo) monitors the reflected energy to infer the presence of flaws, whereas the lower amplitude of refracted signals is ignored. When the reflector is orientated normally with respect to the ultrasonic beam, the received echo signal shows the maximum amplitude. The pulse-echo method also relies on monitoring the amplitude of the backwall echo to identify or confirm the presence of defects. This works well for parts with constant thickness and with planar backwalls. Unfortunately, parts with complex backwalls are common to many industrial sectors. For example, applications such as aerospace structures often require parts with complex shapes. Assessing such parts reliably is not trivial and can cause severe downtime in the aerospace manufacturing processes or during in-service inspections. This work aims to improve the ultrasonic inspectability of parts with complex backwalls, through sending ultrasonic beams from the frontwall side. Ultrasonic phased array probes and state-of-the-art instrumentation allow ultrasonic energy to be sent into a part at wide ranges of focusing depths and steering angles. This allows for tracking of the backwall profile, thus hitting it normally and maximising the amplitude of the reflected echo at any point. However, this work has shown that a cross-sectional scan resulting from multiple ultrasonic beams, which are sent at variable incidence angles, can present significant geometrical distortion and cannot be of much use for accurate defect visualisation and sizing. This paper introduces a generalised algorithm developed to remove geometric distortions and the effect that variable refraction coefficients have on the transmitted and received amplitudes. The algorithm was validated through CIVA simulations for two example parts with complex backwalls, considering isotropic materials.
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