This application claims the benefit of the French patent application No. 2105549 filed on May 27, 2021, the entire disclosures of which are incorporated herein by way of reference.
The present invention relates to a method and a system for an ultrasonic detection of internal defects of a component, in particular for an aircraft.
Although not exclusively, this method is more particularly intended for providing assistance in the inspection of components obtained by a manufacturing method of the DED (standing for “Directed Energy Deposition”) type, and, in particular, during the manufacture of components intended for aircraft, notably transport aircraft.
In a known way, such a DED (or Directed Energy Deposition) manufacturing method is an additive manufacturing (or 3D printing) method in which a material is deposited on a support and focused heat energy is used to melt the material as it is deposited. The material, a powder or a wire, is deposited by a nozzle, and is immediately melted by a laser or electron beam, or by arc deposition technologies (using plasma, for example). This method is most often used with metallic powders or wires (alloys based on aluminum, titanium or nickel, . . . ). DED technologies have several advantages in comparison with more conventional additive manufacturing methods, and notably a high manufacturing speed and the possible manufacture of large components.
It is known that such a DED manufacturing method generates or can generate defects such as porosities or lack of fusion in the manufactured components. In the context of the present invention, internal “defects” of a component are understood to mean an at least partial absence of matter in the material forming the component.
Porosities can generally be detected by usual methods using radiography and ultrasonic measurements.
The difficulty during the inspection of such components manufactured by a DED method concerns the detection of linear defects, generated due to a lack of fusion, which can exhibit various shapes and orientations.
The usual inspections carried out by radiography and ultrasonic measurements do not make it possible to detect such defects, or do so only very partially.
There is thus a need to have a method making it possible to detect any type of defect in a component, for example roundish defects such as porosities or inclusions of denser material (“solid inclusion” being the English expression) and also linear defects such as lack of fusion, and to do so whatever the orientations of these defects in the component may be.
A purpose of the present invention is to meet this need. In order to do this, it relates to a method for an ultrasonic detection of internal defects of a component, in particular for an aircraft.
According to the invention, the method comprises at least the following steps:
In the context of the present invention, the zone of interest corresponds to a spatial zone of the component in which an ultrasonic inspection is carried out.
Thus, due to the gridding of the zone of interest and to the carrying out of measurements in all of the cells of that gridding, data is obtained for the whole of the area of the zone of interest in question, that is to say, of the zone of the component that one wishes to inspect. Moreover, due to a spaced arrangement of the transmitters and receivers, and to the processing of data obtained from all of the transmitters and from all of the receivers arranged in different positions on the ultrasonic measuring device, there is obtained, for each cell, measurements carried out at different and varied transmission and reception angles, which makes it possible to obtain an ultrasonic image of each cell according to different views. It is therefore possible to detect defects in the component which have different orientations and shapes.
The ultrasonic detection method therefore makes it possible to detect all of the defects existing in the zone of interest of the component, and to do so no matter what the spatial orientation of this defect or these defects may be. The method is particularly suitable for detecting linear defects generated during a DED manufacturing method. However, this method can also be used for detecting defects in other types of components, for example welds.
In a preferred embodiment, the processing step also comprises determining, if appropriate, the contour of a defect in the plane of the zone of interest as a function of the overall amplitudes computed for all of the cells of the grid.
Moreover, advantageously, the processing step also comprises computing, if appropriate, the length of a defect from the length between the two cells most distant from each other among all of the cells for which the defect has been detected.
Moreover, advantageously, the gridding comprises identical square-shaped cells, the sides of which have a length greater than one tenth of a so-called acceptance criterion.
Moreover, advantageously, the measuring step consists of generating an ultrasonic signal having a frequency of between 7.5 MHz and 13 MHz.
The present invention also relates to a system for an ultrasonic detection of internal defects of a component, in particular for an aircraft.
According to the invention, the system comprises at least:
In a preferred embodiment, the ultrasonic measuring device comprises a plurality of ultrasonic units, each of the ultrasonic units comprising an ultrasonic transmitter and an ultrasonic receiver, and the ultrasonic units are arranged side by side along a linear bar.
Moreover, advantageously, the ultrasonic measuring device comprises at least 64 ultrasonic transmitters and at least 64 ultrasonic receivers.
Moreover, advantageously, the ultrasonic measuring device comprises a delay line.
Moreover, advantageously, the system comprises a unit for the presentation of the results of the processing implemented by the processing unit.
The system, such as described above, can be used in various applications, notably for carrying out component conformity checks, in particular for components for an aircraft, during their manufacture, or much later during a maintenance or inspection operation.
The appended figures will give a good understanding of how the invention can be embodied. In these figures, identical references denote similar units.
The system 1, shown diagrammatically in
This system 1 is intended for detecting defects in the material 3 of the component 2.
In the context of the present invention, internal “defects” of a component is understood to mean an at least partial absence of matter in the material forming the component. It can notably be a matter of roundish defects such as, for example, porosities or of linear defects such as, for example, lack of fusion.
The system 1 is particularly suitable for analyzing a component 2 whose material 3 has been deposited using a usual manufacturing method of the DED (standing for “Directed Energy Deposition”) type.
In order to do this, the system 1 comprises an ultrasonic measuring device 4, as shown in
This ultrasonic measuring device 4 comprises, as shown in
Each of the N ultrasonic units U1 to UN comprises an ultrasonic transmitter T1 to TN able to generate an ultrasonic signal in a usual way and an ultrasonic receiver R1 to RN able to receive (and detect), and ultrasonic signal in a usual way.
In a preferred embodiment, the integer N is equal to 64 or 128, and preferably equal to 64. In this case, the ultrasonic measuring device 4 therefore comprises 64 ultrasonic transmitters and 64 ultrasonic receivers.
Other numbers N are of course possible in the context of the present invention. Likewise, it is possible to envisage having a number N1 of ultrasonic transmitters and a number N2 of ultrasonic receivers, N2 being an integer different from the integer N1.
By way of illustration (not limiting), the ultrasonic measuring device 4 can comprise 64 ultrasonic units which are spaced from each other by a pitch d0 of between 0.3 and 0.6 mm along the linear bar 5.
Each of the ultrasonic transmitters T1 to TN is therefore able to transmit an ultrasonic signal. In the context of the present invention, the longitudinal waves of the ultrasonic signal are used for the transmission and for the reception.
As described in more detail below, each ultrasonic transmitter T1 to TN of the ultrasonic measuring device 4 is configured for generating an ultrasonic signal Si and for transmitting the ultrasonic signal Si (thus generated) into the component 2, as shown in
Moreover, each ultrasonic receiver R1 to RN of the ultrasonic measuring device 4 is configured for measuring the amplitude of a received ultrasonic signal Sij, namely, as described below, the amplitude of the part of the ultrasonic signal Si (transmitted by an ultrasonic transmitter T1 to TN), which is returned (after reflection) by the component 2, as described below.
It is known that the propagation of an ultrasonic signal in a component (such as the component 2) is characterized, as the case may be, by characteristic (reflection) peaks, which correspond to acoustic impedance breaks in the component, at the interfaces of different materials. In the case where the material 3 is uniform in the component 2, acoustic impedance breaks are generated, as the case may be, at the interface between, on the one hand, the material 3 and, on the other hand, an absence of material, that is to say, a defect such as those described above. Consequently, an ultrasonic signal transmitted into the material (by an ultrasonic transmitter) is reflected by a defect, if it encounters such a defect during its propagation in the material. The ultrasonic signal thus reflected (and detected by an ultrasonic receiver) has a high amplitude, characteristic of the presence of such a defect.
The ultrasonic measuring device 4 is configured for carrying out measurements on a so-called zone of interest ZI of the component 2 shown diagrammatically in
In the context of the present invention, the zone of interest ZI is divided according to a gridding M comprising elementary cells C, as shown in
The successions of operations are implemented successively, ultrasonic transmitter after ultrasonic transmitter, from each of the ultrasonic transmitters T1 to TN of the ultrasonic measuring device 4. Each of the successions of operations comprises, for a given ultrasonic transmitter, the following operations:
These operations are described in more detail below, with reference to an ultrasonic detection method P (
The system 1 also comprises, as shown in
Moreover, in a preferred embodiment, the ultrasonic measuring device 4 comprises a delay line 15 as shown in
Moreover, the system 1 comprises a unit 11 for presenting the results of the processing implemented by the processing part 9 of the processing unit 6. This unit 11 is intended to provide an operator or a system with the result (received by a link 12) of the processing carried out by the processing part 9. In order to do this, the unit 11 can, notably, comprise:
The system 1, such as described above, is able to implement a method P of analysis of the conformity of the material 3 of a component 2, for example such as the one shown in
The method P firstly comprises a measuring step E1 (
This measuring step E1 comprises carrying out measurements on the zone of interest ZI of the component 2 (
The zone of interest ZI is therefore divided according to a gridding M comprising elementary cells C, as shown in
In a preferred embodiment, the gridding M comprises identical square-shaped cells C, the sides of which have a length greater than one tenth of a so-called acceptance criterion. Acceptance criterion is understood to mean the maximum size or length which is accepted for a defect of the component, for example 1 mm. This acceptance criterion notably depends on the component in question and on the envisaged application.
The measuring step E1 consists of successively carrying out, cell C after cell C, for each of the cells C of the gridding M, a plurality of N successions of operations SO.
For any one of the cells C, the N successions of operations SO are implemented successively, ultrasonic transmitter after ultrasonic transmitter, from each of the N ultrasonic transmitters T1 to TN of the ultrasonic measuring device 4.
Each of the N successions of operations SO comprises the following operations:
Consequently, there is obtained, for a given cell C (such as the cell Ck in
By way of illustration,
The method P also comprises a computing step E2, implemented by the computing unit 7. This computing step E2 comprises computing, for each of the cells C of the gridding M, the sum of the amplitudes Aij of all of the measurements MEij carried out in the measuring step E1 for that cell.
Because of this summation, the computing step E2 makes it possible to obtain a so-called overall amplitude for each of the C cells of the gridding M.
The method P also comprises a processing step E3, implemented by the processing part 9, after the computing step E2.
This processing step E3 comprises deducing from the overall amplitudes computed for all of the cells of the gridding, as the case may be, the presence of one or more defects. A defect is considered as being detected in a cell when the overall amplitude (that is to say, the sum of the measured amplitudes) of that cell exceeds a predetermined threshold.
In a preferred embodiment, the processing step E3 consists of determining, in the case of detection of a defect, as a function of the overall amplitudes of the cells detecting a defect, the contour 14 of the defect 13 in the plane of the zone of interest, as shown in
Moreover, in the processing step E3, the processing part 9 can also compute the length D of an identified defect. In order to do this, as shown in
The method P comprises, moreover, a step E4, implemented by the unit 11, comprising presenting and/or transmitting to an operator or to a system, some or all of the results (identification of the defect 13, presentation of the contour 14 of defect 13, value of the length D of the defect 13, . . . ) obtained in the processing step E3. The presentation can be carried out by various usual means in display or printed form.
In a particular embodiment, it is possible to produce a map of the analyzed structure revealing the defects by the intermediary of one or more particular colors. This map can resemble the image I in
The system 1 implementing the method P such as described above, thus allows an efficient detection of all of defects existing in a zone of interest of a component, and to do so no matter what the spatial orientation of this defect or these defects may be.
In fact, due to the gridding M of the zone of interest ZI and to the carrying out of measurements in all of the cells C of that gridding M, the system 1 obtains data for the whole area of the zone of interest ZI in question, that is to say, of the zone of the component 2 that one wishes to inspect. Moreover, due to a spaced arrangement of the ultrasonic units U1 to UN along the linear bar 5 and to the processing of the data obtained from all of the ultrasonic transmitters and from all of the ultrasonic receivers therefore arranged at different positions on the linear bar 5 of the ultrasonic measuring device 4, the system 1 obtains, for each cell C, measurements carried out at different and varied angles of transmission and of reception. This makes it possible to obtain an ultrasonic image of each cell C taken at different views. The system 1 is thus able to detect defects (in the component 2), which exhibit various orientations, and more generally any possible orientation.
The (ultrasonic detection) system 1 therefore makes it possible to detect all of the defects existing in the zone of interest ZI of the component 2, and to do so no matter what the spatial orientation and the shape of that defect or those defects may be. The system 1 is particularly suitable for detecting linear defects generated during the use of a DED manufacturing method. However, this method can also be used for detecting defects in other types of components, for example welds.
The system 1, such as described above, can be used in various applications.
In particular, in a first possible application, the system 1 is used for carrying out conformity checks during the manufacture of a component, for example of an aircraft, and notably during the manufacture of a component by a manufacturing method of the DED type. In this application, the system 1 makes it possible to carry out an accurate, fast and reliable check of the deposited material of the component is such a way as to be able to detect the presence of defects.
In a second possible application, the measurements can be carried out during an assembly operation, or during a subsequent check with the component already fitted, for example during a maintenance operation. In such an application, the system 1 can notably be used for carrying out measurements in particular places of the component, for example in one or more places where it is considered that a defect may exist.
While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
Number | Date | Country | Kind |
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2105549 | May 2021 | FR | national |
Number | Name | Date | Kind |
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20050252296 | Hock | Nov 2005 | A1 |
20220107290 | Jin | Apr 2022 | A1 |
20220281107 | Grimard | Sep 2022 | A1 |
Number | Date | Country |
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102012025535 | Jun 2014 | DE |
3085095 | Feb 2020 | FR |
2022016726 | Jan 2022 | WO |
Entry |
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French Search Report; priority document. |
Number | Date | Country | |
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20220381746 A1 | Dec 2022 | US |