Patent Description:
Currently, there are no methods to ensure accurate and reliable bond strength in composite manufacturing. Inconsistencies may be introduced into a bondline during manufacturing of a composite structure. The inconsistencies may lead to undesirably high re-work and scrap rates.

Currently, composite bond strength is not quantifiable using conventional non-destructive techniques. The inconsistencies in the bondline may be difficult to detect visually or by using non-destructive testing. Some types of inconsistencies in the bondline of a composite structure, such as microporosity, crystallization, and kissing disbonds, may not be currently detectable using non-destructive inspection techniques. Further, the non-destructive testing of the bondline may be at least one of undesirably time-consuming or undesirably costly.

<CIT>, according to its abstract, states that a projection-based x-ray imaging system combines projection magnification and optical magnification in order to ease constraints on source spot size, while improving imaging system footprint and efficiency. The system enables tomographic imaging of the sample especially in a proximity mode where the same is held in close proximity to the scintillator. In this case, a sample holder is provided that can rotate the sample. Further, a z-axis motion stage is also provided that is used to control distance between the sample and the scintillator.

<CIT>, according to its abstract, states that a high-resolution radiation detector is formed by viewing a scintillation crystal with an electronic camera through an optical lens assembly. The material of the scintillation crystal is selected to have a high density, contain a high atomic number element, and have a high index of refraction, such as Bismuth Germinate Oxide, Cadmium Tungstate, or Gadolinium Silicate. A light absorbing coating is applied to the radiation entry surface of the scintillation crystal to further increase the spatial resolution of the detector. In some embodiments of the invention, the optical lens assembly has a large f-number, providing improvements in spatial resolution.

<CIT>, according to its abstract, states that a computerized three-dimensional x-ray tomographic microscopy system is disclosed, comprising source means for providing a source of parallel x-ray beams, staging means for staging and sequentially rotating a sample to be positioned in the path of the x-ray image magnifier means positioned in the path of the beams downstream from the sample, detecting means for detecting the beams after being passed through and magnified by the image magnifier means, and computing means for analyzing values received from the detecting means, and converting the values into three-dimensional representations.

<NPL> discloses an X-ray imaging system which includes an X-ray scintillator, a light detector and a first and second objective lens but this document is silent about a detector housing that houses all these elements.

The present invention provides an X-ray inspection system. The X-ray inspection system comprises an X-ray source, an X-ray scintillator, a light detector, a first objective lens, and a second objective lens. The first objective lens is positioned between the X-ray scintillator and the light detector. The second objective lens is positioned between the first objective lens and the light detector.

The present disclosure also provides a bondline inspection system which falls outside the scope of the present invention. The bondline inspection system comprises an X-ray source assembly, an X-ray detection assembly, and an alignment system. The X-ray detection assembly comprises an X-ray scintillator, at least two objective lenses, and a light detector. The alignment system is physically associated with both the X-ray source assembly and the X-ray detection assembly.

The present disclosure also provides a method of inspecting a bondline within a composite structure which falls outside the scope of the present invention. X-rays are sent into a first surface of the composite structure. X-rays are received at an X-ray scintillator from a second surface of the composite structure. Light is generated from the X-rays received at the X-ray scintillator. The light generated from the X-rays received at the X-ray scintillator is magnified by a first objective lens to form magnified light. The magnified light is directed to a light detector using a second objective lens. Whether the bondline has a desired quality is determined using an output from the light detector.

The present disclosure will now be detailed with reference to the following description and drawings.

The present disclosure recognizes and take into account one or more different considerations. For example, the present disclosure recognizes and takes into account that conventional non-destructive techniques, such as high frequency ultrasound, do not determine small variations in the bondline due to undesirable curing. A laser bond inspection device (LBID) may be used to determine bondline integrity. However, a laser bond inspection device (LBID) may also undesirably break the bondline during the laser bond inspection process. Currently the only way to test bondline integrity is by means of a pull test, which is destructive.

The present disclosure recognizes and takes into account that bondlines in composite structures may be formed using fasteners, co-curing composite portions, bonding the composite portions by curing a bonding adhesive, or by other desirable methods. Fasteners may be used as reinforcement for the bondlines of the composite structures. Fasteners may be used as a failsafe for the composite structures having the bondlines. The fasteners are used as a failsafe because conventional inspection techniques do not provide strength measurements of the bondline.

The present disclosure recognizes and takes into account that the fasteners add to a weight of an aircraft. Removing the fasteners will reduce the weight of the aircraft and improve weight-dependent performance features of the aircraft. The present disclosure additionally recognize and take into account that providing non-destructive inspection for the bondline may allow for bondlines without failsafe fasteners.

The present disclosure recognizes and takes into account that conventional X-ray inspection is undesirable for detecting microporosity and other types of inconsistencies in bondlines in composite structures. Conventional X-ray inspection has undesirably low resolution.

The present disclosure recognizes and takes into account that characteristics of X-ray inspection include a number of pixels of a detector and a flux of X-rays from the X-ray source. Increasing the size of the detector without changing the number of pixels reduces the resolution of the inspection. Increasing the number of pixels without increasing the flex of X-rays, the contrast of the data from the detector is reduced.

The present disclosure recognizes and takes into account that microchannel plates are used in X-ray inspection to amplify signals. Environmental light undesirably affects the microchannel plates. Environmental light may effectively disable the microchannel plates. The present disclosure recognizes and takes into account that X-ray scintillators receive X-rays and generate visible light. X-ray scintillators include structured scintillators and powder scintillators. Powder scintillators include powder having different orientations. Powder scintillators scatter light due to the powder orientation.

The present disclosure recognizes and takes into account that structured scintillators having material in an ordered structure scatters less light than powder scintillators. Structured scintillators are formed of crystals. Structured scintillators may also be referred to as crystal scintillators. Structured scintillators having material in an ordered structure scatter less light than powder scintillators.

The present disclosure recognizes and takes into account that X-ray complementary metal-oxide-semiconductor (CMOS) detectors are used in dental imaging and other small medical imaging. X-ray CMOS detectors may be undesirable in imaging larger areas. Inspecting large areas using X-ray CMOS detectors may take an undesirable amount of time.

The present disclosure recognizes and takes into account that geometrical distortion is created in x-ray imaging. Geometrical distortion increases the difficulty of detecting inconsistencies in the bondline of a composite structure. The present disclosure recognizes and takes into account that it would be desirable to reduce aberration and geometrical distortion in x-ray inspection of composite structures.

The present disclosure recognizes and takes into account that optical systems comprise different lens types. Different lens types perform different functions. For example, relay lenses are used to invert an image or extend the length of a system. As another example, an objective lens, or a series of objective lenses, is used to focus light. An objective lens can be used to reduce or eliminate distortion.

The present invention provides an X-ray inspection system. The X-ray inspection system comprises an X-ray source, an X-ray scintillator, a light detector, and at least two objective lenses.

Turning now to <FIG>, an illustration of a block diagram of an inspection environment is depicted in accordance with the present disclosure. X-ray inspection system <NUM> is present in inspection environment <NUM>. X-ray inspection system <NUM> may be used to inspect composite structure <NUM>. The X-ray inspection system <NUM> may be referred to as bondline inspection system <NUM>.

X-ray inspection system <NUM> comprises X-ray source <NUM>, X-ray scintillator <NUM>, light detector <NUM>, first objective lens <NUM>, and second objective lens <NUM>. First objective lens <NUM> is positioned between X-ray scintillator <NUM> and light detector <NUM>. Second objective lens <NUM> is positioned between first objective lens <NUM> and light detector <NUM>.

First objective lens <NUM> is positioned such that first objective lens <NUM> is first distance <NUM> from X-ray scintillator <NUM>. First distance <NUM> is selected such that first objective lens <NUM> provides magnification <NUM>. According to the present invention, the first distance <NUM> is adjustable.

First objective lens <NUM> has a diameter sufficient to receive all of light <NUM> emitted by X-ray scintillator <NUM>. First objective lens <NUM> is large enough to focus and collimate light <NUM> from X-ray scintillator <NUM>.

First objective lens <NUM> has anti-reflective coating <NUM> configured to selectively block light having wavelengths <NUM> of light <NUM> emitted by X-ray scintillator <NUM>. Wavelengths <NUM> emitted by X-ray scintillator <NUM> is in a specific window. Wavelengths <NUM> emitted by X-ray scintillator <NUM> may be described as high frequency. Wavelengths <NUM> emitted by X-ray scintillator <NUM> may be described as in the green region of visible light.

Anti-reflective coating <NUM> is selected to selectively block light having wavelengths <NUM>. Anti-reflective coating <NUM> reduces or prevents light being reflected from first objective lens <NUM> back to X-ray scintillator <NUM>. The anti-reflective coating <NUM> can reduce noise in X-ray inspection system <NUM>. The anti-reflective coating <NUM> preferably reduces exterior light from outside of X-ray inspection system <NUM>. Anti-reflective coating <NUM> reduces or prevents ghost images in X-ray scintillator <NUM>.

Second objective lens <NUM> has anti-reflective coating <NUM> configured to selectively block light having wavelengths <NUM> of light <NUM> emitted by X-ray scintillator <NUM>. Anti-reflective coating <NUM> is selected to selectively block light having wavelengths <NUM>. Anti-reflective coating <NUM> reduces or prevents light being reflected from second objective lens <NUM> back to X-ray scintillator <NUM>. The anti-reflective coating <NUM> preferably reduces noise in X-ray inspection system <NUM>. The anti-reflective coating <NUM> preferably reduces exterior light from outside of X-ray inspection system <NUM>. Anti-reflective coating <NUM> reduces or prevents ghost images in X-ray scintillator <NUM>.

First objective lens <NUM> and second objective lens <NUM> are configured to receive, magnify, and direct light <NUM> generated from X-rays <NUM> received at X-ray scintillator <NUM>. First objective lens <NUM> and second objective lens <NUM> together focus light <NUM> onto a smaller area than the surface area of X-ray scintillator <NUM>. First objective lens <NUM> magnifies light <NUM> received from X-ray scintillator <NUM> to form magnified light <NUM>. Second objective lens <NUM> receives and compacts magnified light <NUM>.

Second objective lens <NUM> is configured to provide compaction <NUM> of magnified light <NUM>. Compaction <NUM> of magnified light <NUM> provides improved image quality. Compaction <NUM> of magnified light <NUM> provides a reduction in distortion. Second objective lens <NUM> reduces or eliminates negative effects of first objective lens <NUM> on light <NUM>. For example, second objective lens <NUM> reduces or eliminates pincushion, barrel distortion, horizontal non-linearity and vertical non linearity to provide improved image quality. Second objective lens <NUM> compacts and directs magnified light <NUM> to form compacted light <NUM> directed to light detector <NUM>.

Light detector <NUM> comprises one of charge-coupled device (CCD) image detector <NUM> or complementary metal-oxide-semiconductor (CMOS) image detector <NUM>. Light detector <NUM> has pitch <NUM> of at least <NUM> microns, where a micron is a millionth of a meter. Pitch <NUM> is a measured distance from one pixel to another pixel of light detector <NUM>.

X-ray source <NUM> is preferably positioned within X-ray source housing <NUM>. X-ray source assembly <NUM> includes X-ray source housing <NUM> and X-ray source <NUM>.

X-ray scintillator <NUM>, light detector <NUM>, first objective lens <NUM>, and second objective lens <NUM> are preferably positioned within detector housing <NUM>. X-ray detection assembly <NUM> includes detector housing <NUM> and components within detector housing <NUM>.

To inspect bondline <NUM> of composite structure <NUM>, X-ray source assembly <NUM> is positioned relative to first surface <NUM> of composite structure <NUM>. X-ray source assembly <NUM> is positioned such that X-ray source <NUM> faces first surface <NUM>. The X-ray source assembly <NUM> can be positioned such that X-ray source housing <NUM> is in contact with first surface <NUM>.

X-ray detection assembly <NUM> is positioned relative to second surface <NUM> of composite structure <NUM>. Second surface <NUM> is an opposite surface of first surface <NUM> about bondline <NUM> of composite structure <NUM>. The second surface <NUM> may be described as being on a second side of composite structure <NUM>.

X-ray detection assembly <NUM> is positioned such that X-ray scintillator <NUM> is positioned between light detector <NUM> and second surface <NUM>. The X-ray detection assembly <NUM> can be positioned such that detector housing <NUM> is in contact with second surface <NUM>.

To inspect bondline <NUM>, X-ray source <NUM> directs X-rays <NUM> into first surface <NUM> of composite structure <NUM>. The first surface <NUM> may be described as being on a first side of composite structure <NUM>.

X-ray source <NUM> takes any desirable form. X-ray source <NUM> is preferably a macro X-ray source. The x-ray source <NUM> preferably comprises micro focus tubes. When x-ray source <NUM> comprises at least one micro focus tube, resolution can be increased for an image produced by light detector <NUM>. Micro focus tubes generate very small focal spot sizes, typically below <NUM> in diameter. The X-ray source <NUM> is preferably a micro-focused X-ray tube.

X-ray scintillator <NUM> receives X-rays <NUM> that traveled through first surface <NUM>, bondline <NUM>, and second surface <NUM>. X-ray scintillator <NUM> generates light <NUM> from X-rays <NUM> received.

X-ray scintillator <NUM> is preferably a structured scintillator <NUM>. Structured scintillator <NUM> is formed of crystals growing in a structured format.

Light <NUM> travels to first objective lens <NUM>. First objective lens <NUM> receives light <NUM> and forms magnified light <NUM>. Magnified light <NUM> is received by second objective lens <NUM>. Second objective lens <NUM> forms compacted light <NUM> from magnified light <NUM>.

Light detector <NUM> receives compacted light <NUM> and forms output <NUM>. Output <NUM> is sent to computer <NUM>. A determination is made using output <NUM> whether bondline <NUM> has a desired quality. The output <NUM> may be referred to as sensor data. An image formed using output <NUM> can be displayed on display <NUM> of computer <NUM>. The determination is can be performed based on information displayed on display <NUM>. The determination can also be performed based on an image on display <NUM>.

Inconsistencies <NUM> in bondline <NUM> can be identified. Inconsistencies <NUM> include any type of inconsistency present in bondline <NUM>. Inconsistencies <NUM> may comprise microporosity. Inconsistencies <NUM> may comprise crystallization. Inconsistencies <NUM> may comprise a kissing disbond.

X-ray detection assembly <NUM> is configured to maximize the flux collected. X-ray detection assembly <NUM> is configured to receive and process X-rays <NUM> to minimize loss of X-rays <NUM>. For example, X-ray detection assembly <NUM> is sized to collect substantially all X-rays <NUM> exiting second surface <NUM>. X-ray detection assembly <NUM> includes structured scintillator <NUM> rather than a powder scintillator to reduce loss of X-rays <NUM> during generation of light <NUM>.

To collect as much of X-rays <NUM> exiting second surface <NUM> as possible, X-ray detection assembly <NUM> is aligned relative to X-ray source assembly <NUM>. X-ray inspection system <NUM> has alignment system <NUM>. Alignment system <NUM> takes any desirable form. Alignment system <NUM> is configured to align X-ray source assembly <NUM> and X-ray detection assembly <NUM> relative to each other.

Alignment system <NUM> can take the form of magnetic alignment system <NUM>. When alignment system <NUM> takes the form of magnetic alignment system <NUM>, first component <NUM> of magnetic alignment system <NUM> is connected to X-ray source housing <NUM>, and second component <NUM> of magnetic alignment system <NUM> is connected to detector housing <NUM>.

When alignment system <NUM> takes the form of magnetic alignment system <NUM>, one of X-ray source housing <NUM> or detector housing <NUM> may be moved by magnetic force of magnetic alignment system <NUM> when the other of X-ray source housing <NUM> or detector housing <NUM> is moved. A magnetic force of magnetic alignment system <NUM> enables alignment of X-ray source assembly <NUM> and X-ray detection assembly <NUM>. Alignment of X-ray source assembly <NUM> relative to X-ray detection assembly <NUM> affects collection of X-rays <NUM>. If X-ray source assembly <NUM> and X-ray detection assembly <NUM> are offset, X-ray detection assembly <NUM> will collect only a portion of X-rays <NUM>.

When alignment system <NUM> takes the form of magnetic alignment system <NUM>, X-ray inspection system <NUM> may be maneuvered by an operator. When alignment system <NUM> takes the form of magnetic alignment system <NUM>, automated movement of X-ray inspection system <NUM> may be simplified. For example, when alignment system <NUM> takes the form of magnetic alignment system <NUM>, X-ray source assembly <NUM> may be maneuvered by an automated system while X-ray detection assembly <NUM> is moved by magnetic attraction of magnetic alignment system <NUM>.

As depicted, alignment system <NUM> comprises one of magnetic alignment system <NUM> or fiducial alignment system <NUM>. Alignment system <NUM> can be a combination of magnetic alignment system <NUM> and fiducial alignment system <NUM>. For example, fiducial alignment system <NUM> may be used to initially position X-ray source assembly <NUM> and X-ray detection assembly <NUM> relative to composite structure <NUM>. After initially positioning X-ray source assembly <NUM> and X-ray detection assembly <NUM>, magnetic alignment system <NUM> may be used to precisely position X-ray source assembly <NUM> and X-ray detection assembly <NUM> relative to each other.

Alignment system <NUM> can take the form of fiducial alignment system <NUM>. When alignment system <NUM> comprises fiducial alignment system <NUM>, fiducials <NUM> are located on or near composite structure <NUM> for alignment of X-ray inspection system <NUM>. When alignment system <NUM> takes the form of fiducial alignment system <NUM>, X-ray inspection system <NUM> is maneuvered by controller <NUM>.

Controller <NUM> is configured to position X-ray detection assembly <NUM> relative to X-ray source assembly <NUM>. Controller <NUM> is configured to position light detector <NUM> relative to X-ray source <NUM>. Controller <NUM> may be implemented in at least one of hardware or software. Controller <NUM> may be a processor unit in a computer system or a specialist circuit depending on the particular implementation.

Bondline inspection system <NUM> comprises X-ray source assembly <NUM>, X-ray detection assembly <NUM>, and alignment system <NUM>. X-ray detection assembly <NUM> comprises X-ray scintillator <NUM>, at least two objective lenses, and light detector <NUM>. Alignment system <NUM> is physically associated with both X-ray source assembly <NUM> and X-ray detection assembly <NUM>.

Including at least two objective lenses reduces or eliminates chromatic aberrations. The at least two objective lenses are positioned within X-ray detection assembly <NUM> to magnify and compact light <NUM> from X-ray scintillator <NUM>. Although two objective lenses, first objective lens <NUM> and second objective lens <NUM>, are depicted, any desirable quantity of objective lenses may be present in bondline inspection system <NUM>. More than two objective lenses can be present in bondline inspection system <NUM>. Bondline inspection system <NUM> can have three objective lenses, four objective lenses, or more than four objective lenses. Increasing a quantity of objective lenses within X-ray detection assembly <NUM> increases the magnification provided within X-ray detection assembly <NUM>. Increasing a quantity of objective lenses also increases the complexity of X-ray detection assembly <NUM>.

Each objective lens in addition to first objective lens <NUM> improves image quality as system detection capability, however each additional lens adds additional cost and complexity to the system. A quantity of objective lenses in x-ray detection assembly <NUM> may be selected based on a desired image quality for inspecting bondline <NUM> for small porosity, voids, or other small inconsistencies.

X-ray inspection system <NUM> is configured to provide inspection for qualification of composite structure <NUM> with bondline <NUM>. X-ray inspection system <NUM> is configured to send X-rays <NUM> into a surface area of between <NUM> to <NUM> (one to five inches) of first surface <NUM>. X-ray inspection system <NUM> is configured to provide inspection for composite structure <NUM> with bondline <NUM> having a thickness of <NUM> to <NUM> (<NUM> to <NUM> inches).

The illustration of inspection environment <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which the present disclosure may be implemented. Other components in addition to, or in place of, the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in the present disclosure.

For example, although fiducials <NUM> and fiducial alignment system <NUM> are depicted, alignment system <NUM> may take any desirable form. For example, alignment system <NUM> may take the form of a laser tracking alignment system.

In some non-depicted examples, x-ray inspection system <NUM> comprises a third objective lens. In these non-depicted examples, the third objective lens is positioned between second objective lens <NUM> and light detector <NUM>. In some other non-depicted examples, x-ray inspection system <NUM> further comprises a fourth objective lens between the third objective lens and light detector <NUM>.

Turning now to <FIG>, an illustration of an X-ray inspection system is depicted in accordance with the present disclosure. X-ray inspection system <NUM> is a physical implementation of X-ray inspection system <NUM> of <FIG>. X-ray inspection system <NUM> comprises X-ray source assembly <NUM> and X-ray detection assembly <NUM>. X-ray source assembly <NUM> is a physical implementation of X-ray source assembly <NUM> of <FIG>.

X-ray source assembly <NUM> is positioned relative to first surface <NUM> of composite structure <NUM>. X-ray source assembly <NUM> is configured to send X-rays (not depicted) into first surface <NUM> of composite structure <NUM>. An X-ray source (not depicted) is present within housing <NUM> of X-ray source assembly <NUM>.

X-ray detection assembly <NUM> is a physical implementation of X-ray detection assembly <NUM> of <FIG>. X-ray detection assembly <NUM> is positioned relative to second surface <NUM> of composite structure <NUM>. X-ray detection assembly <NUM> receives X-rays (not depicted) that travel through composite structure <NUM>.

An X-ray scintillator (not depicted), at least two objective lenses (not depicted), and a light detector (not depicted) are present inside of detector housing <NUM> of X-ray detection assembly <NUM>. X-ray detection assembly <NUM> is in electronic communication with computer system <NUM>.

As depicted, display <NUM> of computer system <NUM> is displaying image <NUM>. Image <NUM> is created from output of the light detector of X-ray detection assembly <NUM>. Image <NUM> may be used to determine if inconsistencies are present in bondline <NUM>. Image <NUM> may be used to determine if a desired quality is present for bondline <NUM>.

As depicted, inconsistencies <NUM> are present in bondline <NUM> of composite structure <NUM>. X-ray source assembly <NUM> and X-ray detection assembly <NUM> are positioned to inspect portion <NUM> of bondline <NUM> having inconsistencies <NUM>. Inconsistencies <NUM> are visible in image <NUM>.

Turning now to <FIG>, an illustration of an X-ray inspection system is depicted in accordance with the present disclosure. X-ray inspection system <NUM> is a physical implementation of X-ray inspection system <NUM> of <FIG>. X-ray inspection system <NUM> comprises X-ray source <NUM>, X-ray scintillator <NUM>, light detector <NUM>, first objective lens <NUM>, and second objective lens <NUM>. First objective lens <NUM> is positioned between X-ray scintillator <NUM> and light detector <NUM>. Second objective lens <NUM> is positioned between first objective lens <NUM> and light detector <NUM>.

View <NUM> is a simplified view of X-ray inspection system <NUM> of <FIG>. Although not depicted in view <NUM>, X-ray inspection system <NUM> may further comprise other components, such as at least a number of housings, a controller, an alignment system, or any other desirable components.

X-ray source <NUM> directs X-rays <NUM> into first surface <NUM> of composite structure <NUM>. X-rays <NUM> enter composite structure <NUM> and travel through composite structure <NUM>. X-ray scintillator <NUM> receives X-rays <NUM> exiting composite structure <NUM> at second surface <NUM>.

X-ray scintillator <NUM> receives X-rays <NUM> and generates light <NUM>. First objective lens <NUM> magnifies light <NUM> generated from X-rays <NUM> received at X-ray scintillator <NUM>. Second objective lens <NUM> concentrates the magnified light from first objective lens <NUM>.

Second objective lens <NUM> directs compacted light to light detector <NUM>. Output (not depicted) of light detector <NUM> is used to determine if a desired quality is present in bondline <NUM> of composite structure <NUM>.

X-ray inspection system <NUM> provides images with sufficient resolution to detect inconsistencies within bondline <NUM> of composite structure <NUM>. X-ray inspection system <NUM> is configured to provide sufficient resolution and sufficient contrast to detect kissing disbonds, microporosity, crystallization, or other types of inconsistencies within bondline <NUM>.

To provide sufficient resolution, distances between components are set to provide sufficient magnification and collect substantially all of the X-rays and maximize the collection of the generated light. A ratio of distance <NUM> between X-ray source <NUM> and sample <NUM> and distance <NUM> between sample <NUM> and X-ray scintillator <NUM> is selected to provide a desired magnification.

The illustration of X-ray inspection system <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which the present disclosure may be implemented. Other components in addition to, or in place of, the ones illustrated may be used. For example, in some non-depicted illustrative examples, X-ray inspection system <NUM> may include more than two objective lenses.

The different components shown in <FIG> may be combined with components in <FIG>, used with components in <FIG>, or a combination of the two. Additionally, some of the components in <FIG> may be illustrative examples of how components shown in block form in <FIG> may be implemented as physical structures.

Turning now to <FIG>, an illustration of a flowchart of a method for inspecting a bondline within a composite structure is depicted in accordance with the present disclosure. Method <NUM> is a method of inspecting bondline <NUM> within composite structure <NUM> of <FIG>. Method <NUM> may be performed using X-ray inspection system <NUM> of <FIG>. Method <NUM> may be used to inspect bondline <NUM> within composite structure <NUM> of <FIG>. Method <NUM> may be performed using X-ray inspection system <NUM> of <FIG>. Method <NUM> may be used to inspect bondline <NUM> within composite structure <NUM> of <FIG>. Method <NUM> may be performed using X-ray inspection system <NUM> of <FIG>.

Method <NUM> sends X-rays into a first surface of a composite structure (operation <NUM>). Method <NUM> receives X-rays at an X-ray scintillator from a second surface of the composite structure (operation <NUM>). Method <NUM> generates light from the X-rays received at the X-ray scintillator (operation <NUM>). Method <NUM> magnifies the light generated from the X-rays received at the X-ray scintillator by a first objective lens to form magnified light (operation <NUM>). Method <NUM> directs the magnified light to a light detector using a second objective lens (operation <NUM>). Method <NUM> determines if the bondline has a desired quality using an output from the light detector (operation <NUM>). Afterwards, method <NUM> terminates.

The method <NUM> may position an X-ray source housing relative to the first surface of the composite structure prior to sending the X-rays into the first surface of the composite structure using an X-ray source positioned within the X-ray source housing (operation <NUM>). The method <NUM> may further comprise positioning a detector housing relative to the second surface of the composite structure prior to sending the X-rays into the first surface of the composite structure, wherein the X-ray scintillator, the light detector, the first objective lens, and the second objective lens are positioned within the detector housing (operation <NUM>).

The method <NUM> may further comprise positioning the detector housing relative to the second surface of the composite structure comprises aligning the detector housing relative to the X-ray source housing (operation <NUM>).

The method <NUM> may further comprise sending X-rays into the first surface of the composite structure comprises sending X-rays into a portion of the composite structure having a surface area in the range of <NUM> to <NUM> (one to five inches), with a bondline thickness of <NUM> to <NUM> (<NUM> to <NUM> inches) (operation <NUM>).

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatus and methods in the present disclosure. In this regard, each block in the flowcharts or block diagrams may represent a module, a segment, a function, and/or a portion of an operation or step.

In some alternative implementations of the present disclosure, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added, in addition to the illustrated blocks, in a flowchart or block diagram. Some blocks may be optional. For example, in method <NUM>, operations <NUM> through <NUM> may be optional.

Turning now to <FIG>, an illustration of a data processing system in a form of a block diagram is depicted in accordance with the present disclosure. Data processing system <NUM> may be used to implement at least one of computer <NUM> or controller <NUM> of <FIG>.

The data processing system <NUM> may include communications fabric <NUM>. Communications fabric <NUM> provides communications between processor unit <NUM>, memory <NUM>, persistent storage <NUM>, communications unit <NUM>, input/output (I/O) unit <NUM>, and display <NUM>. Memory <NUM>, persistent storage <NUM>, communications unit <NUM>, input/output (I/O) unit <NUM>, and display <NUM> are examples of resources accessible by processor unit <NUM> via communications fabric <NUM>.

Processor unit <NUM> serves to run instructions for software that may be loaded into memory <NUM>. Processor unit <NUM> may be a number of processors, a multi-processor core, or some other type of processor, depending on the particular implementation. Further, processor unit <NUM> may be implemented using a number of heterogeneous processor systems in which a main processor is present with secondary processors on a single chip. Processor unit <NUM> may be a symmetric multi-processor system containing multiple processors of the same type.

Memory <NUM> and persistent storage <NUM> are examples of storage devices <NUM>. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, data, program code in functional form, and other suitable information either on a temporary basis or a permanent basis. Storage devices <NUM> also may be referred to as computer readable storage devices in these examples. Memory <NUM>, may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage <NUM> may take various forms, depending on the particular implementation.

Persistent storage <NUM> may contain one or more components or devices. For example, persistent storage <NUM> may be a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage <NUM> also may be removable.

Communications unit <NUM>, may provide for communications with other data processing systems or devices. Communications unit <NUM> can be a network interface card. Communications unit <NUM> may provide communications through the use of either or both physical and wireless communications links.

Input/output (I/O) unit <NUM> allows for input and output of data with other devices that may be connected to data processing system <NUM>. For example, input/output (I/O) unit <NUM> may provide a connection for user input through a keyboard, a mouse, and/or some other suitable input device. Further, input/output (I/O) unit <NUM> may send output to a printer. Display <NUM> provides a mechanism to display information to a user.

Instructions for the operating system, applications, and/or programs may be located in storage devices <NUM>, which are in communication with processor unit <NUM> through communications fabric <NUM>. The instructions can be in a functional form on persistent storage <NUM>. These instructions may be loaded into memory <NUM> for execution by processor unit <NUM>. The processes of the different embodiments may be performed by processor unit <NUM> using computer-implemented instructions, which may be located in a memory, such as memory <NUM>.

These instructions are referred to as program instructions, program code, computer usable program code, or computer readable program code that may be read and executed by a processor in processor unit <NUM>. The program code in the different embodiments may be embodied on different physical or computer readable storage media, such as memory <NUM> or persistent storage <NUM>.

Program code <NUM> is located in a functional form on computer readable media <NUM> that is selectively removable and may be loaded onto or transferred to data processing system <NUM> for execution by processor unit <NUM>. Program code <NUM> and computer readable media <NUM> can form computer program product <NUM>. The computer readable media <NUM> may be computer readable storage media <NUM> or computer readable signal media <NUM>.

Computer readable storage media <NUM> may include, for example, an optical or magnetic disk that is inserted or placed into a drive or other device that is part of persistent storage <NUM> for transfer onto a storage device, such as a hard drive, that is part of persistent storage <NUM>. Computer readable storage media <NUM> also may take the form of a persistent storage, such as a hard drive, a thumb drive, or a flash memory, that is connected to data processing system <NUM>. In some instances, computer readable storage media <NUM> may not be removable from data processing system <NUM>.

Computer readable storage media <NUM> can be a physical or tangible storage device used to store program code <NUM> rather than a medium that propagates or transmits program code <NUM>. Computer readable storage media <NUM> is also referred to as a computer readable tangible storage device or a computer readable physical storage device. In other words, computer readable storage media <NUM> is a media that can be touched by a person.

Alternatively, program code <NUM> may be transferred to data processing system <NUM> using computer readable signal media <NUM>. Computer readable signal media <NUM> may be, for example, a propagated data signal containing program code <NUM>. For example, computer readable signal media <NUM> may be an electromagnetic signal, an optical signal, and/or any other suitable type of signal. These signals may be transmitted over communications links, such as wireless communications links, optical fiber cable, coaxial cable, a wire, and/or any other suitable type of communications link. In other words, the communications link and/or the connection may be physical or wireless.

The program code <NUM> may be downloaded over a network to persistent storage <NUM> from another device or data processing system through computer readable signal media <NUM> for use within data processing system <NUM>. For instance, program code stored in a computer readable storage medium in a server data processing system may be downloaded over a network from the server to data processing system <NUM>. The data processing system providing program code <NUM> may be a server computer, a client computer, or some other device capable of storing and transmitting program code <NUM>.

The different components illustrated for data processing system <NUM> are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. The the present disclosure may be implemented in a data processing system including components in addition to and/or in place of those illustrated for data processing system <NUM>. Other components shown in <FIG> can be varied. The different embodiments may be implemented using any hardware device or system capable of running program code. As one example, data processing system <NUM> may include organic components integrated with inorganic components and/or may be comprised entirely of organic components excluding a human being. For example, a storage device may be comprised of an organic semiconductor.

The processor unit <NUM> may take the form of a hardware unit that has circuits that are manufactured or configured for a particular use. This type of hardware may perform operations without needing program code to be loaded into a memory from a storage device to be configured to perform the operations.

For example, when processor unit <NUM> takes the form of a hardware unit, processor unit <NUM> may be a circuit system, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform a number of operations. With a programmable logic device, the device is configured to perform the number of operations. The device may be reconfigured at a later time or may be permanently configured to perform the number of operations. Examples of programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices. With this type of implementation, program code <NUM> may be omitted, because the processes for the different embodiments are implemented in a hardware unit.

The processor unit <NUM> may be implemented using a combination of processors found in computers and hardware units. Processor unit <NUM> may have a number of hardware units and a number of processors that are configured to run program code <NUM>. Here some of the processes may be implemented in the number of hardware units, while other processes may be implemented in the number of processors.

A bus system may be used to implement communications fabric <NUM> and may be comprised of one or more buses, such as a system bus or an input/output bus. Of course, the bus system may be implemented using any suitable type of architecture that provides for a transfer of data between different components or devices attached to the bus system.

Additionally, communications unit <NUM> may include a number of devices that transmit data, receive data, or both transmit and receive data. Communications unit <NUM> may be, for example, a modem or a network adapter, two network adapters, or some combination thereof. Further, a memory may be, for example, memory <NUM>, or a cache, such as that found in an interface and memory controller hub that may be present in communications fabric <NUM>.

The present disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, an illustration of an aircraft manufacturing and service method is depicted in accordance with the present disclosure. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> takes place. Thereafter, aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

With reference now to <FIG>, an illustration of an aircraft is depicted in which the present disclosure may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> of <FIG> and may include airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the present disclosure may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM>. As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.

For example, "at least one of item A, item B, or item C" may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, "at least one of" may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

The present disclosure may be used during at least one of component and subassembly manufacturing <NUM>, system integration <NUM>, or maintenance and service <NUM> of <FIG>. For example, X-ray inspection system <NUM> of <FIG> may be used during component and subassembly manufacturing <NUM> to inspect composite structure <NUM> of <FIG>. X-ray inspection system <NUM> may be used to inspect portions of aircraft <NUM> such as airframe <NUM> or portions of interior <NUM>.

The present disclosure can provide an X-ray inspection system and methods for inspecting a composite structure. The present disclosure can provide a method to nondestructively verify bondline integrity of a bonded composite structure.

The present disclosure may use phase contrast imaging in combination with microscopic imaging and high resolution nano-focus X-ray technology. The present disclosure may provide a system to conduct spot checks of bondline integrity by super high-resolution X-ray imaging and microscopy. The present disclosure can detect small anomalies and change in a bondline after curing, such as micro-porosity, crystallization, or kissing disbonds. The present disclosure can utilize nano-focus X-ray magnification and optical scintillation magnification.

Claim 1:
An X-ray inspection system (<NUM>) comprising:
an X-ray source housing (<NUM>) configured for being brought into contact with a first surface (<NUM>) of a composite structure (<NUM>);
a detector housing (<NUM>) configured for being brought into contact with a second surface (<NUM>) of the composite structure (<NUM>) opposite the first surface (<NUM>);
an X-ray source (<NUM>) positioned within the X-ray source housing (<NUM>);
an X-ray scintillator (<NUM>) positioned within the detector housing (<NUM>), wherein the X-ray scintillator (<NUM>) is a structured scintillator (<NUM>) formed of crystals grown in a structured format;
a light detector (<NUM>) positioned within the detector housing (<NUM>);
a first objective lens (<NUM>) positioned within the detector housing (<NUM>) and between the X-ray scintillator (<NUM>) and the light detector (<NUM>) such that the first objective lens (<NUM>) is a first distance (<NUM>) from the X-ray scintillator (<NUM>), wherein the first distance (<NUM>) is adjustable, and wherein the first objective lens (<NUM>) has an anti-reflective coating (<NUM>) configured to reduce or prevent light being reflected from first objective lens (<NUM>) back to X-ray scintillator (<NUM>); and
a second objective lens (<NUM>) positioned within the detector housing (<NUM>) and between the first objective lens (<NUM>) and the light detector (<NUM>).