Lamb wave-based inspection methods show promise in long range Nondestructive Evaluation (NDE) of thin metallic and composite plates. This NDE strategy is typically implemented in a pitch-catch configuration of one actuator and at least one sensor. Despite non-contact methods such as laser ultrasonics and air-coupled transducers, the most common approach relies on contact transducers. Transducer placement is usually performed manually and positional errors and variations in contact conditions are therefore inevitable. Thus, this study investigates the potential improvement in measurement reliability and repeatability through the use of an automated deployment system. The system is comprised of two subsystems: 1) A gel deployment subsystem to deposit the desired amount of couplant at the target location. 2) A transducer deployment subsystem to lower the transducer onto test article. In addition to a detailed description of the developed prototype systems, their combined reliability is demonstrated for experiments on an aluminum panel in a broad frequency range. The results are compared to those obtained via transducers positioned by multiple different human operators. These benchmark experiments are conducted with varying degree of aids, such as placement templates and weights. Furthermore, measurements from manual placement are processed both manually as well as automatically to further illustrate the need for fully automated NDE capabilities. It is shown that the automated prototype transducer deployment system not only reduces manual labor but achieves slightly improved repeatability as compared to an experienced human operator with positioning aids.
In order to support the continued trend of increased use of composite materials especially in aviation, efficient testing systems need to be developed. The anisotropic material properties of composites allow for high specific stiffnesses and strengths. However, some failure modes in composite structures cannot be identified through visual inspection and to ensure the health of the structures, a time-consuming and costly inspection approach must be taken. Often, this approach includes disassembly and premature part replacements. Thus, complete nondestructive inspection (NDI) and monitoring of composite structures in aviation is virtually nonexistent. Hence, there is a need to introduce an autonomous inspection method to reduce time and cost, while increasing aircraft reliability. To this end, several recent advancements of a mobile robotic platform and related algorithms for Lamb wave-based inspection of aircraft surfaces are presented here. The robots are envisioned to be operated in a low cardinality swarm, where each robot employs guided ultrasound technology to collaboratively inspect plate-like components. For the purpose of implementing a fully autonomous platform, simultaneous localization and mapping (SLAM) methods are combined with Lamb wave-based NDI techniques. Specifically, it is demonstrated that a novel Lamb wave-based edge seeking and tracing methodology can contribute to increasing testing efficiency, with the overarching goal of creating a full map of the tested structure including all potential flaws.
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