Phased Array Imaging of Complex-Geometry Composite Components

Area of Science:

• Aerospace Engineering
• Materials Science
• Nondestructive Evaluation

Background:

• Aerospace engine components feature complex geometries and advanced composite materials, challenging traditional inspection methods.
• Increasing surface curvature and intricate microstructures reduce the sensitivity and selectivity of conventional nondestructive evaluation (NDE).
• Existing immersion testing methods face limitations due to signal interpretation complexities arising from water-component interface reflections and refractions.

Purpose of the Study:

• To present a general approach for enhanced nondestructive evaluation of complex aerospace components.
• To overcome the limitations of traditional NDE methods in inspecting intricate geometries and microstructures.
• To demonstrate the effectiveness of ultrasonic phased array (PA) technology in immersion testing for aerospace applications.

Main Methods:

• Combining ultrasonic phased array (PA) technology with immersion testing for continuous scanning and volumetric rendering.
• Utilizing advanced computing for rapid ray tracing in anisotropic media with a 256-channel parallel array architecture.
• Employing both reflected and transmitted signals through the component using arrays in a yoke configuration for full-volume inspection.

Main Results:

• The developed approach successfully accounts for refraction at the water-component interface by reconstructing interface geometry.
• The method overcomes dead zone limitations, improving sensitivity to shallow subsurface defects.
• Experimental results demonstrate the robust detection of defects such as porosity and waviness in complex composite specimens, including fan blades.

Conclusions:

• Ultrasonic phased array (PA) technology in an immersion configuration provides a viable and effective solution for inspecting complex aerospace components.
• The combination of advanced computing and PA technology enables comprehensive, full-volume inspection of parts with challenging geometries and materials.
• This approach significantly enhances the capability to detect critical defects in composite aerospace structures.