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Real-time full-field ultrasonic inspection of composites using acoustography

Many small composite parts undergo manual pulse-echo scan because 1) the set-up time for and automated scan is unjustifiably long and 2) the automated scan does not provide the flexibility to cope with frequent angle changes in a complex geometry part. Manual scans can be time consuming, laborious, and are prone to errors due to operator fatigue and subjectivity. What is required is a full-field ultrasonic inspection system analogous to real time radiography that allows the operator to perform ultrasonic inspection by manipulating the part under a systems field of view. In this paper, we will present an acoustography-based ultrasonic inspection system developed under a SBIR (Small Business Innovation Research) award that is bringing this vision to into reality. Acoustography is the ultrasonic analog of radiography and photography. A unique, wide area 2D detector, called acousto-optic (AO) sensor, is used to directly convert ultrasound into visual images; much like a fluorescent screen is able to convert x-rays into visual images. It offers the potential for providing the NDT engineer with a large field of view (e.g. 6”x 6” or larger) and a capability to inspect complex shaped parts in real time.