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Ultrasound Camera: High Resolution Real Time Freehand Scanning of Composite Laminates

Ultrasound Camera: High Resolution Real Time Freehand Scanning of Composite Laminates. Bob Lasser, Dan Slaski , David Rich, John Kula Imperium, Inc . Tyler Holmes, Jeff Kollgaard Boeing Commercial Airplanes. Imperium . Involved in NDT since 1996 Sole provider of UT camera technology

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Ultrasound Camera: High Resolution Real Time Freehand Scanning of Composite Laminates

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  1. Ultrasound Camera: High Resolution Real Time Freehand Scanning of Composite Laminates Bob Lasser, Dan Slaski, David Rich, John Kula Imperium, Inc. Tyler Holmes, Jeff Kollgaard Boeing Commercial Airplanes

  2. Imperium • Involved in NDT since 1996 • Sole provider of UT camera technology • Applications in aerospace, petrochemical, and medical settings • Production and in-service implementations • Address solution to complexity of NDT equipment and lack of trained technicians

  3. Agenda • Ramp damage challenge for industry • Potential scenario of ramp damage • Acoustocam solution to industry challenge • Technical background • Recent results • Upcoming developments

  4. Industry Challenge • Flight Safety Foundation estimates ramp damage costing operators up to $10 billion annually • Upwards of 27,000 ramp incidents, 1 per 1,000 departures • Primary composite structures present unique challenges • New York Times Article August 2013: “Composite materials have created new challenges for airline mechanics, who need new maintenance tools and skills.“

  5. Industry Challenge • NDT equipment or trained personnel is typically not at remote locations • Composite based aircraft could be damaged at locations where NDT personnel are not present • Need device and procedure which minimizes downtime due to ramp damage

  6. Possible Scenario • Damage, although rare, occurs by impact on a composite aircraft • No NDT expert is on-site • Line mechanic notes visible impact damage • Aircraft out of service until NDT personnel can be brought onsite

  7. Possible Scenario • Time to get NDT technicians, equipment, and perform tests can be lengthy • When damage is noted, damage is within allowable limits, plane is cleared to fly. • Aircraft out-of-service costs can reach $50,000 or more per day

  8. Future Scenario • Damage occursand is noted • Line mechanic contacts expert via web session • Line mechanic sets up Acoustocam • Calibration could be done remotely while mechanic holds probe on clean section or standard

  9. Future Scenario • Mechanic scans section via simple procedure and monitored by expert in real time • Expert confirms remotely that damage is within criteria • Total incurred time: 30 minutes • Aircraft downtime cost: minimal

  10. Acoustocam • Makes UT imaging simple • Addresses lack of trained NDT technicians • Presents real-time C-scan and A-scan • High resolution • Available in fully automated modality to minimize setup • Provides large area scanned image to address damage larger than acquisition area • Easy to transmit and monitor remotely • Compliant with ASTM E317

  11. Imperium’s Patented ArchitectureApplies optical imaging techniques to ultrasound Optical Architecture: Optical Sensor (CCD) Flash Lens Ultrasonic Architecture: Source Transducer Acoustic Lens Ultrasonic Sensor

  12. Acoustocam Architecture

  13. Imaging Array – 100 micron pixels120 rows x 120 columns = 14,400 pixels

  14. Acoustocam User Interface No Defect Found Delamination at 0.115”

  15. Acoustocam Calibration Procedure

  16. Resolution Panel Typical Resolution taken in scanning tank

  17. ANA Airlines • In Q1 2013, performed a study at ANA Airlines at Haneda Airport, Tokyo • Trained NDT personnel • Investigated several types of structures • Following trial, ANA Airlines requested NDT procedure for 787, offered to implement device • Requested further work be performed on chemical milling application using angle beam

  18. ANA Airlines “This instrument is quite helpful for catching the image of internal structures and detecting the delamination quickly with C-scan mode. Imperium’s Camera is easy to set up and handle. Therefore, our NDT inspectors prefer to use the Imperium camera. Moreover, it is capable of remote usage by line mechanics at local airports. Consequently, ANA would like to use the Imperium Camera in the future and for remote inspection.” Hiroshi Kobayashi ANA Senior Manager Structural Engineering

  19. Upcoming Developments • Two dimensional presentation of C-scan in fielded unit • Embedded angle beam capability to perform shear mode for crack imaging • Boeing procedure development in NDT manual for Level II for 787 expected in Q4 2013.

  20. Imperium, Inc.5901-F Ammendale RdBeltsville, Maryland 20705 301-431-2900 / 301-431-0200 fax  www.ImperiumInc.com

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