High Resolution, Low Cost Ultrasound Camera for In-service Composite NDI

Robert Lasser, Marvin Lasser, Ron Westernik, John Kula, David Rich

Imperium, Inc.

Imperium Formed in 1996 Focused solely on ultrasound camera

technology In development for 10 years, now

selling commercially Implement for different embodiments

of ultrasound camera

Medical Image of Finger:

Easy-to-Interpret Image Examples

Industrial Detection of Fault:

Imperium Conventional

Defect

Bone

Industry Sectors

IndustrialIndustrial

UnderwaterUnderwater

BiometricsBiometrics

MedicalMedical

Sampling of Customers

Imperium ArchitectureApply optical imaging techniques to ultrasound

Optical Sensor

Lens

Imperium Architecture

Ultrasound Sensor Acoustic Lens Set Acoustic Flashlight

Through Transmission

Source TransducerTargetAcoustic Lens Imaging Array

Imaging Array

Piezoelectric Layer

Pre-amp/ detection

Signal Conditioning

Multiplexing

Pin Grid ArrayPackage

Ultrasound (piezoelectric)

material Read out

integrated circuit(ROIC)

Wire bonds

I500 to I600

Through Transmission of Composite Laminate

Three inches

Sound Sound TransmitterTransmitter

ArrayArray

VideoVideo

LensLens

TargetTarget

Subsurface Subsurface faultfault

Pulse Echo – 50/50 Beamsplitter

Pulse echo image of quarter

Acoustic Acoustic beamsplitterbeamsplitter

WaterWater

Pulse Echo of Composite Laminate

One inch

Pulse Echo of Quarter

One inch

Front_of_quarter_1.mpg

Front_of_quarter_1.mpg

Beamsplitter

Source transducer

Target

Imaging Array

LCD

Acoustic Lens

Camera Head Cutaway

B-scan versus C-scan

Defect

Defect

Impact Damage in Composite Structure

Leading Edge Inspection

One inch

Pulse Echo of Honeycomb Composite

One inch

Range Gating

Gate 1

Gate 2

Gate 3

Range Gating for Depth: Pick the C-scan plane of interest

“Transparent” A-scan Sensor

Integrated A-scan for Flaw Detector Functionality

Presentation of Imagery and A-scan/ Match Gates

Set A-scan gates, automatically changes C-scan gates

Production Scanning Results: ATK Thiokol

Graphite/epoxy laminate defect standardwith embedded Teflon wafers

Hex nut and paper clip placedon surface

UT camera scan with stitchingalgorithm applied - 0.3” scan increment

Conventional immersion scan - 2.25 MHz, 0.25” diameter transducer - 0.075 scan increment

Gridlines/Sizing

Future Developments: Pulse Echo

Handheld portion goes from 4 lbs. to 2 lbs.

Current Development: ‘Camcorder’ Handheld

Handheld portion goes from 4 lbs. to under 2 lbs.

Focus with finger

Strap

Grip

New Control Unit

Current Development: ‘Camcorder’ Handheld

Time of flight: color code different depths

2

2

3

3

1

Increments to be selected by user (e.g. 1 mm)

Blue: Level 1

Red: Level 2

Yellow: Level 3

Future Developments: Through Transmission

Lack of trained NDI personnelLack of trained NDI personnel Use by non-certified personnelUse by non-certified personnel SIMPLE, SIMPLE, SIMPLESIMPLE, SIMPLE, SIMPLE Remotely monitored in real timeRemotely monitored in real time WirelessWireless Program began in early 2007Program began in early 2007

Boeing Remote NDI Program

Remote Wireless NDI Program

C-scan, A-scan, Audio, Video of inspection

Audio, Control of camera

Successful demonstration Fall 2008Successful demonstration Fall 2008 Equipment at Boeing’s Everett, WA Equipment at Boeing’s Everett, WA

production facilityproduction facility Remotely monitored at Boeing’ Remotely monitored at Boeing’

GoldCare center in Seattle, WAGoldCare center in Seattle, WA Pilot program with airlines during 2009Pilot program with airlines during 2009

Boeing Remote NDI Program