Systems and methods for in-situ cure monitoring and defect detection
Inventors
Hudson, Tyler B • Palmieri, Frank L. • Abbott, Trenton B. • Seebo, Jeffrey P. • BURKE, ERIC R.
Assignees
National Aeronautics and Space Administration NASA • Analytical Mechanics Associates Inc
Publication Number
US-11360053-B2
Publication Date
2022-06-14
Expiration Date
2039-12-02
Interested in licensing this patent?
MTEC can help explore whether this patent might be available for licensing for your application.
Abstract
Non-destructive evaluation (NDE) systems and methods are provided for monitoring objects being manufactured during a cure or consolidation process and for detecting defects that occur during the cure or consolidation process or to detect conditions of the process that can lead to the occurrence of defects. Information acquired by the NDE system during the cure or consolidation process can be used to adjust one or more parameters of the process in real-time to prevent defects from occurring or to reduce the number and/or severity of defects that occur during the cure or consolidation process.
Core Innovation
The invention provides non-destructive evaluation (NDE) systems and methods for monitoring parts being manufactured during the cure or consolidation process to detect defects occurring during the cure or to detect conditions of the process that can lead to the occurrence of defects. The NDE system uses information acquired during the cure or consolidation process to adjust one or more parameters of the process in real-time to prevent defects or reduce their number and/or severity during the cure process.
The NDE system enables in-situ inspection of laminates in high-temperature and/or high-pressure environments required for curing. It includes an ultrasonic testing (UT) scanning system that acquires UT images of the part during curing and is housed in a vessel designed either for use inside industrial ovens or autoclaves. The vessel and system protect sensitive electronics by using thermal insulation and can include cooling systems, such as liquid nitrogen cooling, to withstand extreme environments. The UT scanning system components have been modified in some embodiments to withstand autoclave pressures, allowing the vessel to be less pressure-resistant while maintaining functionality.
The problem being addressed is the need for a rapid and inexpensive NDE system for composite aerospace parts to monitor curing processes and detect defects as they form. Prior art methods have not demonstrated defect detection, localization, and quantification during cure. Defects such as porosity and fiber waviness form during resin cure cycles and can lead to thermal-chemical deformation, warpage, cracking, and delamination if cure reactions are non-uniform or if gases are trapped. Existing cure monitoring techniques do not provide real-time defect detection and process modeling validation. Hence, a system capable of real-time in-situ monitoring and defect detection to improve part quality and manufacturing outcomes is required.
Claims Coverage
The patent includes three independent claims covering an NDE system, a method for in-situ monitoring during cure, and a computer program for monitoring and defect detection during cure.
NDE system for in-situ monitoring during cure with ultrasonic testing
A vessel configured to resist high temperature and/or high pressure of a curing chamber, housing an ultrasonic testing scanning system with a UT transducer and a mold acting as a build plate. The system acquires ultrasonic waves passing through the mold into the part under cure and converts reflections into UT electrical signals processed by a processor running a cure monitoring and defect detection algorithm.
Method for in-situ monitoring during cure with ultrasonic testing
Generating ultrasonic waves with a UT scanning system inside a vessel resistant to high temperature and/or pressure of a curing chamber, passing waves into a part in contact with a mold, receiving reflected waves converted to electrical signals, and performing a cure monitoring and defect detection algorithm with a processor to detect defects occurring during the cure.
Computer program for in-situ cure monitoring and defect detection
Computer instructions embodied on a non-transitory medium for execution by a processor to perform a cure monitoring and defect detection algorithm that processes UT electrical signals generated by a UT scanning system inside a vessel resistant to chamber environment, detecting defects occurring during the cure process, optionally including instructions to perform a cure process control algorithm to adjust cure parameters based on detection results.
The claims cover a comprehensive system, method, and software for in-situ ultrasonic cure monitoring and defect detection using a pressure and temperature resistant vessel and UT scanning system, including real-time processing to detect defects and optionally control and adjust cure parameters.
Stated Advantages
Provides real-time, in-situ detection and localization of defects forming during the cure process, enabling unprecedented data availability for validation of cure defect models.
Enables understanding of how cure cycle variables affect part quality, reducing probability of failure and improving manufacturing methods and models.
Allows deployment in high-temperature and high-pressure environments such as autoclaves through design of pressure-resistant vessels and cooled scanning components.
Supports adjustment of cure parameters in real-time, either manually or automatically, to prevent or reduce defects during the cure process.
Documented Applications
Monitoring and defect detection during cure of aerospace-grade composite parts in industrial ovens or autoclaves for thermoset and thermoplastic materials.
Automated ultrasonic cure monitoring in extreme environments to detect porosity and other defects such as fiber waviness during manufacturing of carbon fiber reinforced polymer composites.
Interested in licensing this patent?