Ultrasonic testing method and ultrasonic testing device using this

An ultrasonic wave is sent from a transmission element to a test element to produce a plate wave in the test element, and the plate wave propagating through the test element is received by a reception element to thereby test the test element on the propagation route of the plate wave. The other probe that is the other reception element or transmission element is disposed between the transmission element and the reception element. A probe holding mechanism that has support legs contacting the surface of the test element and keeps constant an angle of the other probe with respect to the surface of the test element is allowed to support the other probe. And, the other probe is allowed to cross over in non-contact the propagation route of the plate wave extending from the transmission element to the reception element by means of support legs.

FIELD OF THE INVENTION

The present invention relates to an ultrasonic testing method for transmitting an ultrasonic wave from a transmitter to generate a plate wave in a test piece and receiving at a receiver the plate wave passed through the test piece to inspect the test piece along the propagation path of the plate wave, and an ultrasonic testing device using the ultrasonic testing method.

BACKGROUND OF THE INVENTION

One of such ultrasonic testing devices as described above is known where a sensor head is provided comprising two or more of the transmitters and the receivers disposed at both ends of the center point and particularly held at a uniform angle (the incident angle) to the test piece for scanning the surface of the test piece with no direct contact (See Patent Document 1). It is essential for maintaining the incident angle to a uniform degree to match different modes of the relationship between the incident angle of the ultrasonic wave and the product of ultrasonic frequency and test piece thickness with their respective characteristic curves.

However, if the surface of the test piece is undulated or waved, the incident angle between the transmitter or receiver and the surface of the test piece may hardly be maintained at a uniform degree during the scanning action with no direct contact of the sensor head, thus interrupting the inspecting action with the plate wave.

Alternatively, another testing method is known for inspecting a test piece with the transmitter and receiver placed directly on the test piece. However, the another method also fails to propagate the plate wave up to the receiver after the point on the propagation path of the plate wave where the transmitter or receiver is placed directly on the test piece, hence permitting no use of two or more of the receivers.

More specifically, the conventional methods allows the transmitter or receiver to be disposed across the propagation path of the plate wave which extends through the target region of a test piece to be inspected when the inspection depend fundamentally on the leak wave or the reflection of the ultrasonic wave. As a result, the degree of freedom of the testing action will be limited due to a limited target area of the test piece. Also, with no use of two or more transmitters or receivers, the testing action may hardly be improved in the efficiency.

SUMMARY OF THE INVENTION

It is hence a first object of the present invention, in view of the foregoing aspects, to provide an ultrasonic testing method for, while increasing the degree of freedom for allocating a transmitter and a receiver, ensuring the action of inspection at higher degree of freedom with less limitation of the target area of a test piece to be inspected and to an ultrasonic testing device using this ultrasonic testing method.

It is a second object of the present invention to provide an ultrasonic testing method for allocating a set of receivers thus to improve the efficiency of the action of inspection and to an ultrasonic testing device using this ultrasonic testing method.

For achievement of the object of the present invention, an ultrasonic testing method for transmitting an ultrasonic wave from a transmitter to generate a plate wave in a test piece and receiving at a receiver the plate wave passed through the test piece to inspect the test piece along the propagation path of the plate wave is provided comprising the steps of: providing a probe, which acts as either another transmitter or another receiver, between the transmitter and the receiver which are arranged for transmitting or receiving the ultrasonic wave across a gaseous substance; mounting the transmitter, the receiver, and the probe on probe holding mechanisms respectively which have support legs thereof placed directly on the surface of the test piece, which is selected from aerospace devices, composite materials, and lengthened materials having curves, bends, or branches, and are arranged movable in relation to the test piece so that the transmitter or the receiver can remain held at a desired angle to the surface of the test piece; holding the support legs in direct contact with the surface of the test piece at a location off the propagation path of the plate wave extending from the transmitter to the receiver so that the probe is suspended by the support legs to bridge, with no direct contact, over the propagation path while the probe holding mechanisms are arranged to move the transmitter, the receiver, and the probe simultaneously in relation to the test piece; and passing the plate wave beneath the probe while directing the probe to transmit the ultrasonic wave or receive the plate wave.

As another feature of the present invention, an ultrasonic testing method for transmitting an ultrasonic wave from a transmitter to generate a plate wave in a test piece and receiving at a receiver the plate wave passed through the test piece to inspect the test piece along the propagation path of the plate wave is provided comprising the steps of: emitting the plate wave at the forward route from the transmitter and receiving its reflection reflected by a target region of the test piece with the receiver, the transmitter and the receiver both arranged for transmitting or receiving the ultrasonic wave across a gaseous substance; mounting the transmitter and the receiver on probe holding mechanisms respectively which have support legs thereof placed directly on the surface of the test piece, which is selected from aerospace devices, composite materials, and lengthened materials having curves, bends, or branches, and are arranged movable in relation to the test piece so that the transmitter or the receiver can remain held at a desired angle to the surface of the test piece; holding the support legs in direct contact with the surface of the test piece at a location off the propagation path of both the forward route of the plate wave and the reflection of the plate wave so that the transmitter and the receiver are suspended by the support legs to bridge, with no direct contact, over the propagation path of both the forward route of the plate wave and the reflection of the plate wave while the probe holding mechanisms are arranged for moving the transmitter and the receiver simultaneously in relation to the test piece; and passing the plate wave emitted from the transmitter, reflected by the target region of the test piece, and propagated towards the receiver beneath the transmitter or the receiver located on the way of the propagation path while transmitting the ultrasonic wave from the transmitter or receiving the reflection of the plate wave with the receiver.

Each of the foregoing methods may be modified in which the probe is a focusing type probe. Alternatively, the test piece may be divided into target regions to be inspected to which the receivers are allocated respectively.

The method may further be modified in which the transmitter and the receiver are moved in relation to the test piece along a direction which extends at a right angle to the propagation path of the plate wave. Alternatively, the transmitter and the receiver may be moved in relation to the test piece along a direction aligned with the propagation path of the plate wave.

An ultrasonic testing device having a transmitter for emitting an ultrasonic wave towards a test piece to generate a plate wave in the test piece and a receiver for receiving the plate wave passed through the test piece, whereby the test piece can be inspected along the propagation path of the plate wave by the receiver receiving the plate wave,

according to the present invention is provided comprising probe holding mechanisms for holding the transmitter and the receiver respectively which are arranged for transmitting or receiving the ultrasonic wave across a gaseous substance, each the probe holding mechanism having support legs thereof placed directly on the surface of the test piece, which is selected from aerospace devices, composite materials, and lengthened materials having curves, bends, or branches, and arranged movable in relation to the test piece so that the transmitter or the receiver can remain held at a desired angle to the surface of the test piece; a supporting frame provided to which the probes holding mechanisms are mounted so that the transmitter and the receiver can move simultaneously in relation to the test piece; and pressing members provided for urging the support legs of the probe holding mechanisms by pressure directly against the surface of the test piece downwardly of the supporting frame at a location off the propagation path of the plate wave so that the transmitter and the receiver are suspended by the support legs to bridge, with no direct contact, over the propagation path of the plate wave.

Another ultrasonic testing device for use with any of the foregoing methods according to the present invention is provided as characterized in that the transmitter and the receiver are held by their respective probe holding mechanisms of which the support legs are spaced from each other to clear at least the propagation path of the plate wave, and each of the probe holding mechanisms is mounted to a supporting frame while remains urged by a pressing member against the supporting frame so that its support legs are placed directly on the surface of the test piece and is further accompanied with a rocking mechanism provided between the probe holding mechanism and the supporting frame for rocking its transmitter or receiver on the axis which extends at a right angle to the propagation path of the plate wave in relation to the supporting frame.

A further ultrasonic testing device for use with any of the foregoing methods according to the present invention is provided as characterized in that the supporting legs of the probe holding mechanism are equipped with wheels for running thus to move the transmitter and receiver in relation to the test piece.

A still further ultrasonic testing device for transmitting an ultrasonic wave from a transmitter to generate a plate wave in a test piece and receiving at a receiver the plate wave passed through the test piece to inspect the test piece along the propagation path of the plate wave is provided as characterized in that the transmitter and the receiver are held by their respective probe holding mechanisms, each probe holding mechanism having support legs thereof placed directly on the surface of the test piece and arranged for holding the transmitter or receiver at a uniform angle to the surface of the test piece, the support legs of each probe holding mechanism are spaced from each other to clear at least the propagation

path of the plate wave, and each of the probe holding mechanisms is mounted to a supporting frame while remains urged by a pressing member against the supporting frame so that its support legs are placed directly on the surface of the test piece and is further accompanied with a rocking mechanism provided between the probe holding mechanism and the supporting frame for rocking its transmitter or receiver on the axis which extends at a right angle to at least the propagation path of the plate wave in relation to the supporting frame.

The ultrasonic testing method and the ultrasonic testing device using the method according to the present invention allows each probe to be held by its corresponding probe holding mechanism and the transmitter to be suspended by the support legs of the probe holding mechanism to bridge, with no direct contact, over the propagation path of the plate wave, whereby the plate wave can hardly be interrupted while the allocation of the transmitter and the receiver is improved in the degree of freedom with the target area to be inspected of the test piece less limited thus ensuring a higher effectiveness of the testing action.

Also, since an extra probe which may be a transmitter or a receiver is disposed between the transmitter and the receiver, either the transmission of plural kinds of the ultrasonic wave or the reception of the ultrasonic wave can be implemented at two or more locations, thus increasing the efficiency of the testing action.

Other objects, arrangements, and advantages will be apparent from the following description of some embodiments of the present invention.

DESCRIPTION OF NUMERALS AND SYMBOLS

BEST MODES FOR EMBODYING THE INVENTION

A first embodiment of the present invention will be described referring to the accompanying drawingsFIGS. 1 to 7.

As shown inFIG. 5andFIGS. 1A to 1C, an ultrasonic testing device1is designed for transmitting an ultrasonic wave from the transmitter20in a scan head10with the use of a plate wave transducer3which is controlled by a personal computer2(referred to simply a PC hereinafter). While the ultrasonic wave is propagated between the support legs46of a probe holding mechanism40awhich contains a transmitter20and the support legs46of another probe holding mechanism40bwhich contains a receiver30, it generates a plate wave Ws in a test piece100. This allows a leak wave Wi to be received and transferred via a pre-amplifier4, a filters5, and an A/D converter6to the PC2where it is subjected to arithmetic operations. The PC2also turns a scanner8on via a driver7for starting the scanning action of the scan head10to detect any flaw in the test piece100. A sensor10x is provided between the scan head10and the test piece100for acquiring a data about the scanning position of the scan head10.

The scan head10comprises, as best shown inFIGS. 2 and 3, a supporting frame11supporting a set of the probe holding mechanisms40, the transmitter20, the receiver30, and the probe holding mechanisms40. The probe holding mechanism40comprises a direct-acting bearing42, a pressing member43, a rocking mechanism44, a housing45, the support legs46, a tightening clamp47, and a shielding member49.

The probe holding mechanism40is joined by the direct-acting bearing42to the supporting frame11so that its shaft41can move vertically of the supporting frame11. The shaft41remains urged by the pressing member43, such as a compression coil spring, to press against the test piece100downwardly of the supporting frame11. The rocking mechanism44consists mainly of a convex, arcuate side44aprovided on one end of the shaft41and a concave, arcuate side44bprovided on the housing45, whereby the housing45can be rocked about the Y′ axis which extends along at least the Y axis. As the result, the support legs46come equally into direct contact with the upper surface of the test piece100, thus holding the transmitter20and the receiver30at constant angles to the upper surface of the test piece100. The rocking mechanism44may be arranged for rocking movement about any axis other than the Y′ axis.

The support leg46consists mainly of a leg portion46alocated at each corner of the four-sided bottom of the housing45and a wheel46bmounted to the leg portion46afor running along the Y so as to roll directly on the upper surface of the test piece100with smoothness. The tightening clamp47tightly clamps probe supporting shaft47awhich extends across a window45aprovided in the housing45. This allows each of the transmitter20and the receiver30to be held at a desired degree of the incident (receivable) angle θ to the test piece100.

FIG. 6is a graphic diagram showing the relationship between the product FT of the frequency F of the ultrasonic wave and the thickness T of the test piece100and the incident angle θ at different modes (denoted by A0to A5and S0to S7) of the plate wave Ws when the test piece100is made of a steel plate. While the relationship at each mode is satisfied, the plate wave Ws at the mode is generated in the test piece100and can thus be applied to inspection of a target region O of the test piece100as shown inFIG. 1.

FIG. 7illustrates waveforms of the leak wave Wi produced at the target region and received by the receiver30. While a portion of the ultrasonic wave passed through the target region of the test piece100is first measured, the remaining Wa of the ultrasonic wave passed directly through the air is received with a delay of time. When the target region O has no defect, its resultant waveform is normally as large as shown inFIG. 7A. If the target region O has a defect D such as a peel, its resultant waveform as the lead wave Wi measured first is as small as shown inFIG. 7B. The shielding member49mounted to one side of the housing45has a function for delaying the propagation and thus reception through the air of the ultrasonic wave. The shielding member49may be made of paper or synthetic resin material.

Some variations of the action of testing the test piece100will be described referring toFIG. 1. In the variations of the testing action shown inFIGS. 1A to 1C, the ultrasonic wave Wo is emitted from the transmitter20to the test piece100where it generates a forward plate wave Ws. The resultant leak wave Wi passed through the test piece100is then received by the receiver30.

Each of the transmitter20, the first receiver30a, and the second receiver30bused in those variations of the testing action is installed in the housing45as supported by the four support legs46mounted to the outer edges of the housing45for sitting directly on the upper surface of the test piece100. As shown inFIGS. 1B and 1C, the supporting legs46allows the transmitter20and the first receiver30ato be distanced with no direct contact from the test piece100while bridging over the forward plate wave Ws propagated through the test piece100.

In the variation of the action shown inFIG. 1A, the first receiver30ais located between the transmitter20and the second receiver30b. Accordingly, two of the target regions O of the test piece100are designated between the transmitter20and the first receiver30aand between the first receiver30aand the second receiver30b. Since the propagation path of the forward plate wave Ws is not disturbed by the support legs46, the first receiver30acan be located between. This allows the leak wave Wi to be received at two different positions, hence increasing the area to be inspected with positional accuracy.

Alternatively, the transmitter20may be disposed between the first receiver30aand the second receiver30bas shown inFIG. 1D. This allows the leak wave Wi to be received as a transmitted wave by the first receiver30aand as a reflected wave Wr by the second receiver30b.

Moreover, the second receiver30bmay be disposed between the transmitter20and the first receiver30a, as shown inFIG. 1E, for receiving as the leak wave Wi the reflection Wr of the ultrasonic wave produced by a defect D. This is advantageous because the leak wave Wi is received regardless of the orientation of the second receiver30bas is equally applicable to the arrangement shown inFIG. 1A.

FIG. 4illustrates a feasible example for conducting the variations of the testing action shown inFIG. 1. As apparent, the test piece100has an I-shape which comprises a first flange100a, a second flange100b, a web100d, a third flange100f, and a fourth flange100gas extending in two opposite directions frontwardly and rearwardly of the paper sheet (along the Y direction). The transmitter20and the four receivers30ato30dare held by their respective probe holding mechanisms40ato40eand joined to the supporting frame11of a channel form. The sensor head10carrying the probe holding mechanisms40ato40eis movable for running with the wheels46bof the mechanisms40ato40ealong the Y direction.

In action, the forward plate wave Ws emitted from the transmitter20and propagated through the first flange100aseparates at a first branching point100cinto two along the second flange100band the web100d. The plate wave Ws is further separated at a second branching point100einto two along the third flange100fand the fourth flange100gbefore received as the leak waves Wi by the corresponding receivers30. Accordingly, since its ultrasonic wave is received simultaneously by a group of positions, the testing action can be improved in the operational efficiency.

Other embodiments of the present invention will be described. Like components are denoted by like numerals as those of the previous embodiments and will be explained in no more detail.

FIG. 8illustrates a second embodiment of the present invention in which the transmitter20and the receiver30are implemented by focusing type probes S2of which the oscillator is curved. This allows the incident angle θ to be set to a desired degree ranging widely from θ1to θ2. Accordingly, the testing action can respond to small undulations of the surface of the test piece100which may interrupt the action of the probe holding mechanisms40and overcome any fitting fault between the support legs46and the test piece100.

FIG. 9illustrates a third embodiment of the present invention in which the wheels46bof the support legs46are arranged at a right angle, ninety degrees, to those of the first embodiment. More specifically, the probe holding mechanisms40are classified into probe holding mechanisms40L equipped with the wheels46band the transmitters30and probe holding mechanisms40M equipped with the wheels46band the receivers40. Accordingly, since its scanning action along the X direction is enabled, the testing action can respond to undulations of the surface or XY plane of the test piece100in combination with the function of the rocking mechanisms44.

FIG. 10illustrates a fourth embodiment of the present invention (which is not disclosed in claims but explained as a reference) in which a pair of a probe holding mechanism40ccarrying the second receiver30band a probe holding mechanism40acarrying the transmitter20are aligned along the Y direction. Also, a probe holding mechanism40bcarrying the first receiver30ais provided for receiving a portion of the forward plate wave Ws transmitted across a defect D while the probe holding mechanism40creceives the reflection Wr of the plate wave.

FIG. 11illustrates a fifth embodiment of the present invention which is differed by the fact that the probe holding mechanism40is supported by three of the support legs46. In this embodiment, the transmission and reception of the transmission wave Wo and the leak wave Wi is carried out between the support legs46which thus guarantee no interruption of the propagation of the plate wave Ws, ensuring the smoothness of the testing action. This embodiment is advantageous particularly when the probes20,30are positioned at edges of the target region O of the test piece100. In case that the probe holding mechanism40is placed to bridge the target region O to be inspected, the other embodiments are favorable.

The present invention is not limited to the method and the arrangement of the embodiments described above and various changes and modifications may be made without departing from the scope of the present invention. The present invention is applicable to an ultrasonic wave propagating method and an ultrasonic propagating device and an ultrasonic testing device using the method for propagation of a plate wave Ws between the probe (a transmitter or a receiver) and the test piece100through not only the air but also any gas.

INDUSTRIAL APPLICABILITY

The ultrasonic wave testing method and apparatus according to the present invention are favorable for use in the inspection of composite or lengthened materials such as aerospace components or propellers of an air craft for flaws or defects at stability and quickness.