David S. Forsyth

Model-based inverse methods for bolt-holt eddy current (BHEC) inspections

This work presents a comprehensive approach for model-based inversion of crack characteristics using eddy current nondestructive evaluation (NDE) and includes a demonstration using a bolt-hole eddy-current (BHEC) technique. Data were acquired using standard eddy current hardware for crack and notch samples of varying size and profile. The inversion results were found to be accurate within 10% for sizing the depth of through cracks and able to accurately bin mid-bore cracks by size.

Progress on the development of automated data analysis algorithms and software for ultrasonic inspection of composites

Progress is presented on the development and implementation of automated data analysis (ADA) software to address the burden in interpreting ultrasonic inspection data for large composite structures. The automated data analysis algorithm is presented in detail, which follows standard procedures for analyzing signals for time-of-flight indications and backwall amplitude dropout. ADA processing results are presented for test specimens that include inserted materials and discontinuities produced under poor manufacturing conditions.

Localization and Characterization of Fatigue Cracks Around Fastener Holes Using Spherically Focused Ultrasonic Probes

Results are presented from laboratory experiments and simulations that demonstrate the ability to localize fatigue cracks around fastener holes using spherically focused ultrasonic probes for shear-wave inspections. For the experiments, fatigue cracks were created in aluminum plates in a testing frame under cyclic loading. With the exceptions of one specimen with a mid-bore crack and another with a “through” crack, the remaining specimens contain surface-breaking cracks. All of the specimens were inspected for the cracks intersecting the back wall, and some were flipped over and re-inspected with the crack intersecting the front surface. Parameter and variable sensitivity studies were performed using CIVA Simulation Software. In contrast to C-scans where detection and localization of small cracks can be very difficult, modeling and initial experimental results demonstrate that cracks can be accurately located in “True” B-scans (B-scans projected in the part along the beam path). Initial results show that ...

Progress on automated data analysis algorithms for ultrasonic inspection of composites

Progress is presented on the development and demonstration of automated data analysis (ADA) software to address the burden in interpreting ultrasonic inspection data for large composite structures. The automated data analysis algorithm is presented in detail, which follows standard procedures for analyzing signals for time-of-flight indications and backwall amplitude dropout. New algorithms have been implemented to reliably identify indications in time-of-flight images near the front and back walls of composite panels. Adaptive call criteria have also been applied to address sensitivity to variation in backwall signal level, panel thickness variation, and internal signal noise. ADA processing results are presented for a variety of test specimens that include inserted materials and discontinuities produced under poor manufacturing conditions. Software tools have been developed to support both ADA algorithm design and certification, producing a statistical evaluation of indication results and false calls us...

Enhanced image processing methods for GMR array inspections of multilayer metallic structures

The objective of this paper is to present a comprehensive approach to image processing for Giant Magnetoresistive (GMR) array sensors with sheet current sources for the inspection of fatigue cracks in complex metallic structures. The approach incorporates optimal phase angle adjustment, array sensitivity compensation, fastener site identification, an adaptive edge evaluation and removal algorithm and a classification metric. Processing examples are presented that highlight the benefits of these algorithms for improving crack detection for challenging edge and fastener spacing conditions.

Design and demonstration of automated data analysis algorithms for ultrasonic inspection of complex composite panels with bonds

To address the data review burden and improve the reliability of the ultrasonic inspection of large composite structures, automated data analysis (ADA) algorithms have been developed to make calls on indications that satisfy the detection criteria and minimize false calls. The original design followed standard procedures for analyzing signals for time-of-flight indications and backwall amplitude dropout. However, certain complex panels with varying shape, ply drops and the presence of bonds can complicate this interpretation process. In this paper, enhancements to the automated data analysis algorithms are introduced to address these challenges. To estimate the thickness of the part and presence of bonds without prior information, an algorithm tracks potential backwall or bond-line signals, and evaluates a combination of spatial, amplitude, and time-of-flight metrics to identify bonded sections. Once part boundaries, thickness transitions and bonded regions are identified, feature extraction algorithms ar...

Nondestructive damage characterization of complex aircraft structures by inverse methods: Advances in multiscale models

The use of coupled integral equations and anomalous currents allows us to efficiently remove ‘background effects’ in either forward or inverse modeling. This is especially true when computing the change in impedance due to a small flaw in the presence of a larger background anomaly. It is more accurate than simply computing the response with and without the flaw and then subtracting the two nearly equal values to obtain the small difference due to the flaw. The problem that we address in this paper involves a ’SplitD’ probe that includes complex, noncircular coils, as well as ferrite cores, inserted within a bolt hole, and exciting both the bolt hole and an adjacent flaw. This introduces three coupled anomalies, each with its on ’scale.’ The largest, of course, is the bolt hole, followed (generally) by the probe, and then the flaw. The overall system is represented mathematically by three coupled volume-integral equations. We describe the development of the model and its code, which is a part of the gener...

Model-based inverse methods for sizing cracks of varying shape and location in bolt-hole eddy current (BHEC) inspections

A comprehensive approach is presented to perform model-based inversion of crack characteristics using bolt hole eddy current (BHEC) techniques. Data was acquired for a wide range of crack sizes and shapes, including mid-bore, corner and through-thickness crack types, and from both standard eddy current hardware and a prototype BHEC system with z-axis position encoding. Signal processing algorithms were developed to process and extract features from the 2D data sets, and inversion algorithms using VIC-3D generated surrogate models were used for inverting crack size. New model results are presented, which now address the effect of having a corner crack at an edge and a through crack adjacent to two edges. A two-step inversion process was implemented that first evaluates the material layer thickness, crack type and location, in order to select the most appropriate VIC-3D surrogate model for subsequent crack sizing inversion step. Inversion results for select mid-bore, through and corner crack specimens are p...

Damage localization using ultrasonic methods in multi-layered metallic structures

Results are presented from a highly collaborative project that builds on previous research designed to improve ultrasonic (UT) localization of damage in mutli-layer metallic structures. One of the primary objectives of the project is to test existing acoustic models for cracks around fastener holes, and further develop a model as necessary to achieve the accuracy required for Air Force applications. For the first phase of the project, CIVA modeling results have been compared to ultrasonic measurements on aluminum plates with fatigue cracks and EDM notches at different locations around through-thickness holes. Variables include the diameter of the holes, length/width of notches/cracks, position of notches/cracks on the hole (angle with respect to the probe) and position in depth (surface, mid bore, backwall and through thickness). Baseline measurements have also been made on side-drilled and spherical-tip holes. Modeling challenges include accurately accounting for reflections arising from the cracks and t...

Model benchmarking and reference signals for angled-beam shear wave ultrasonic nondestructive evaluation (NDE) inspections

For model benchmark studies, the accuracy of the model is typically evaluated based on the change in response relative to a selected reference signal. The use of a side drilled hole (SDH) in a plate was investigated as a reference signal for angled beam shear wave inspection for aircraft structure inspections of fastener sites. Systematic studies were performed with varying SDH depth and size, and varying the ultrasonic probe frequency, focal depth, and probe height. Increased error was observed with the simulation of angled shear wave beams in the near-field. Even more significant, asymmetry in real probes and the inherent sensitivity of signals in the near-field to subtle test conditions were found to provide a greater challenge with achieving model agreement. To achieve quality model benchmark results for this problem, it is critical to carefully align the probe with the part geometry, to verify symmetry in probe response, and ideally avoid using reference signals from the near-field response. Suggested reference signals for angled beam shear wave inspections include using the ‘through hole’ corner specular reflection signal and the full skip’ signal off of the far wall from the side drilled hole.For model benchmark studies, the accuracy of the model is typically evaluated based on the change in response relative to a selected reference signal. The use of a side drilled hole (SDH) in a plate was investigated as a reference signal for angled beam shear wave inspection for aircraft structure inspections of fastener sites. Systematic studies were performed with varying SDH depth and size, and varying the ultrasonic probe frequency, focal depth, and probe height. Increased error was observed with the simulation of angled shear wave beams in the near-field. Even more significant, asymmetry in real probes and the inherent sensitivity of signals in the near-field to subtle test conditions were found to provide a greater challenge with achieving model agreement. To achieve quality model benchmark results for this problem, it is critical to carefully align the probe with the part geometry, to verify symmetry in probe response, and ideally avoid using reference signals from the near-field response. Suggeste...