NASA Technical Reports Server (NTRS) 20150003433: Method and Apparatus for Non-Destructive Evaluation of Materials

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(12) United States Patent
(lo) Patent No.: (cid:9) US 8,928,316 B2
Goldfine et al. (45) Date of Patent: (cid:9) Jan. 6, 2015
(54) METHOD AND APPARATUS FOR 324/519, 658, 661, 686, 718, 754.28;
NON-DESTRUCTIVE EVALUATION OF 702/35, 38, 47, 52, 57-59, 127, 182,
MATERIALS 702/183, 185; 73/760, 763, 774, 780,
73/862.626, 335.04
(75) Inventors: Neil J. Goldfine, Newton, MA (US); See application file for complete search history.
Andrew P. Washabaugh, Chula Vista,
CA (US); Robert Lyons, Pelham, MA (56) References Cited
(US); Zachary Thomas, Cambridge,
U.S. PATENT DOCUMENTS
MA (US); David A. Jablonski,
Whitman, MA (US); Christopher 4,348,635 A * 9/1982 (cid:9) Wright et al . (cid:9) ................. (cid:9) 324/559
Martin, Concord, MA (US) 4,814,690 A 3/1989 (cid:9) Melcher et al.
5,015,951 A (cid:9) * 5/1991 (cid:9) Melcher (cid:9) ........................ (cid:9) 324/232
(73) Assignee: JENTEK Sensors, Inc., Waltham, MA (Continued)
(US)
OTHER PUBLICATIONS
(*) Notice: (cid:9) Subject to any disclaimer, the term of this
ASTM WK8211 "Standard Guide for Nondestructive Testing of
patent is extended or adjusted under 35
Polymer Matrix Composites Used in Aerospace Applications," Des-
U.S.C. 154(b) by 411 days.
ignation: E2533-09, (Jul. 2009).
(21) Appl. No.: 13/297,933 (Continued)
(22) Filed: (cid:9) Nov. 16, 2011 Primary Examiner Hoai-An D Nguyen
(74) Attorney, Agent, or Firm Hamilton, Brook, Smith &
(65) (cid:9) Prior Publication Data Reynolds, P.C.
US 2012/0126803 Al (cid:9) May 24, 2012
(57) ABSTRACT
Methods and apparatus for characterizing composite materi-
Related U.S. Application Data
als for manufacturing quality assurance (QA), periodic
(60) Provisional application No. 61/414,008, filed on Nov. inspection during the useful life, or for forensic analysis/
16, 2010, provisional application No. 61/524,520, material testing. System are provided that relate eddy-current
filed on Aug. 17, 2011. sensor responses to the fiber layup of a composite structure,
the presence of impact damage on a composite structure with
(51) Int. Cl.
or without a metal liner, volumetric stress within the compos-
GOIR 33112 (cid:9) (2006.01) ite, fiber tow density, and other NDE inspection requirements.
GOIN27182 (cid:9) (2006.01) Also provided are systems that determine electromagnetic
GOIR 33110 (cid:9) (2006.01) material properties and material dimensions of composite
GOIR 33100 (cid:9) (2006.01) materials from capacitive sensor inspection measurements.
(52) U.S. Cl. These properties are related to the presence of buried defects
CPC ............ GOIR 33110 (2013.01); GOIR 3310064 in non-conductive composite materials, moisture ingress,
(2013.01); GOIR 3310094 (2013.01) aging of the material due to service or environmental/thermal
USPC ............ 324/242; 324/238; 324/239; 324/243 exposure, or changes in manufacturing quality.
(58) Field of Classification Search
USPC ......... 324/216, 228, 237-240, 456, 500, 512, 8 Claims, 12 Drawing Sheets
100
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US 8,928,316 B2
Page 2
(56) (cid:9) References Cited Goldfine, "Uncalibrated, Absolute Property Estimation and Mea-
surement Optimization for Conducting and Magnetic Media Using
U.S. PATENT DOCUMENTS Imposed w-k Magnetometry," Doctoral Thesis, Massachusetts Insti-
tute of Technology, Cambridge, MA, pp. 1-139, (Sep. 1990).
5,345,514 A * 9/1994 Mandavieh et al. (cid:9) .......... 382/152 Goldfine, et al., "Eddy Current Sensor Networks for Aircraft Fatigue
5,453,689 A 9/1995 Goldfine et al.
Monitoring," ASNT Materials Evaluation, Aerospace Health Moni-
5,747,999 A * 5/1998 Yamaoka (cid:9) ...................... 324/501
5,895,439 A * 4/1999 Fisher et al . (cid:9) .................... 702/36 toring, 61(7):1-13, (Jul. 2003).
6,188,218 B1 * 2/2001 Goldfine et al . (cid:9) .............. 324/243 Goldfine, et al., "Rapid Nonlinear `System' Identification for NDT,
6,380,747 B1 4/2002 Goldfine et al. Using Sensor Response Databases," Mat. Eval., 66(7):1-12, (Jul.
6,784,662 B2 * 8/2004 Schlicker et al . (cid:9) ............. 324/242 2008).
6,992,482 B2 1/2006 Shay et al. Hashin, "Analysis of Properties of Fiber Composites with
7,161,350 B2 * 1/2007 Goldfine et al . (cid:9) .............. 324/238 Anisotropic Constituents," J. App. Mech., 46(3):543-550, (Sep.
7,839,282 B1 * 11/2010 Mathur et al . (cid:9) ................ 340/562
1979).
8,264,243 B2 * 9/2012 Tarui et al . (cid:9) .................... 324/663
2003/0071615 Al* 4/2003 Schlicker et al . (cid:9) ............. 324/242 Melcher, "Continuum Electromechanics," The MIT Press, Cam-
2003/0164700 Al* 9/2003 Goldfine et al . (cid:9) .............. 324/235 bridge, MA (1981).
2004/0004475 Al* 1/2004 Goldfine et al . (cid:9) .............. 324/242 Park, J.B., et al., "Electromechanical Modeling of Unidirectional
2004/0056654 Al* 3/2004 Goldfine et al . (cid:9) .............. 324/239 CFRP Composites under Tensile Loading Condition," Composites:
2004/0066188 Al* 4/2004 Goldfine et al . (cid:9) .............. 324/228 Part A, 33:267-275, (2002).
2004/0225474 Al* 11/2004 Goldfine et al . (cid:9) .............. 702/183
Russell, John D., "Composites Affordability Initiative: Transitioning
2004/0232911 Al* 11/2004 Schlicker et al . (cid:9) ............. 324/242
Advanced Aerospace Technologies through Cost and Risk Reduc-
2007/0120561 Al* 5/2007 Goldfine et al . (cid:9) .............. 324/238
2010/0045277 Al* 2/2010 Goldfine et al . (cid:9) .............. 324/209 tion," The AMMTIAC Quarterly, 1(3):3-6, (2006).
2012/0123699 Al* 5/2012 Kawata et al . (cid:9) .................. 702/35 Wang, X., et al., "Electromechanical Behavior of Carbon Fiber,"
OTHER PUBLICATIONS Carbon, 35(5): 452-453, (1997).
Wang, X., et al., "Electromechanical Study of Carbon Fiber Com-
Goldfine, "Magnetometers for Improved Materials Characterization posites," J. Mater. Res., 13 (11):3081-3092, (Nov. 1998).
in Aerospace Applications," Materials Evaluation, pp. 396-405,
(Mar. 1993). * cited by examiner
(cid:9)
U.S. Patent ,Tan. 6, 2015 (cid:9) Sheet 1 of 12 (cid:9) US 8,928,316 B2
110
Instrument
Motion
Recorder
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Fixture
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Motion (cid:9)
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141 (cid:9)
130
Fig. 1
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U.S. Patent (cid:9)
Jan. 6, 2015 (cid:9) Sheet 2 of 12 US 8,928,316 B2
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Fig. 2A
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U.S. Patent (cid:9)
Jan. 6 2015 (cid:9) Sheet 3 of 12 US 8,928,316 B2
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U.S. Patent (cid:9) Jan. 6, 2015 (cid:9) Sheet 6 of 12 US 8,928,316 B2
705
Process impedance response
Identify fiber wraps from response
711
709
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1 YES
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Position sensor at net location
Fig. 7
U.S. Patent (cid:9) Jan. 6, 2015 (cid:9) Sheet 7 of 12 (cid:9) US 8,928,316 B2
800
Start
801
803
Processing the impedances to
obtain a current property image
805
Registering the current property image
with a baseline property image
807
Differencing the registered images
809
Determining an amount of damage based
on the property change
End
Fig. 8
U.S. Patent (cid:9)
Jan. 6, 2015 (cid:9) Sheet 8 of 12 (cid:9) US 8,928,316 B2
900
to Ft
901
905 (cid:9)
............
Processing the first impedances to
obtain a first property image
characterizing the composite overwr
907 "
Processing the second impedances to
obtain a second property image
characterizing the liner
909
Analyzing the first and second property
images to identify damage.
End
Fig. 9