Real Time 2D Ultrasound Camera Imaging: A Higher Resolution Option to Phased Array Bob Lasser Randy Scheib Imperium, Inc.

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1 Real Time 2D Ultrasound Camera Imaging: A Higher Resolution Option to Phased Array Bob Lasser Randy Scheib Imperium, Inc. Beltsville

2 Imperium Involved in NDT since 1996 Sole provider of UT camera technology Applications in aerospace, petrochemical, and medical settings Production and in-service implementations Address solution to complexity of NDT equipment and lack of trained technicians

3 Customer Sampling 3

4 Why Industry Needs A New NDT Device Lack of trained NDT personnel Need higher POD Advances in imaging technology A picture is worth 1000 words System is answer to time and cost pressures

5 Acoustocam Makes UT imaging simple Addresses lack of trained NDT technicians Presents real-time C-scan and A-scan Amplitude and time of flight High resolution One Touch calibration Provides large area scanned image to address damage larger than acquisition area Easy to transmit and monitor remotely Compliant with ASTM E317

6 Optical Architecture: Imperium s Patented Architecture Applies optical imaging techniques to ultrasound Flash Ultrasonic Architecture: Lens Optical Sensor (CCD) Source Transducer Acoustic Lens Ultrasonic Sensor

7 Acoustocam Architecture

8 Imaging Array 100 micron pixels 120 rows x 120 columns = 14,400 pixels

9 Acoustocam User Interface No Defect Found Delamination at 0.115

10 2D Scanning 10

11 Amplitude Time of Flight 11

12 Boeing Certified Procedure 787 NDT Manual: Part4, of the 787 Non- Destructive Testing Manual Drafted procedure for composite damage assessment Delaminations, skin to stiffener disbonds

13 Composite Damage Damage occurs on a composite aircraft No NDT expert is on-site Line mechanic notes visible impact damage Aircraft out of service until NDT personnel can be brought onsite

14 Possible Scenario Time to get NDT technicians, equipment, and perform tests can be lengthy When damage is noted, damage is within allowable limits, plane is cleared to fly. Aircraft out-of-service costs can reach $50,000 or more per day

15 Future Scenario Damage occurs and is noted Line mechanic contacts expert via web session Line mechanic sets up Acoustocam Calibration could be done remotely while mechanic holds probe on clean section or standard

16 ANA Airlines In Q1 2013, performed a study at ANA Airlines at Haneda Airport, Tokyo Trained NDT personnel Investigated several types of structures Following trial, ANA Airlines requested NDT procedure for 787, offered to implement device

17 Corrosion Mapping

18 Storage Tank Bottom Mapping 18

19 B-scan vs. C-scan Phased Array Acoustocam

20 Resolution Study: Acoustocam vsphased Array Investigated axial, lateral, and elevation resolution Used Omniscan MX2 Both systems working at 5 MHz Did mathematical study, then took data to compare expected results

21 Omniscan PAUT System Test Settings: Probe: 5L64-NW1 (5 MHz) Wedge: SN1-0L5L64 Mode: Phased array Focal Depth: 0.1 Focal Law: Linear sector with overlap Skew Direction: 90 0 (straight down mode) Scan Offset: 0 Index Offset: 0 Element Quantity: 8 First Element: 1 Last Element: 64 Thickness: 0.25 Surface: Flat plate

22 AcoustocamSystem Frequency: 5 MHz Number of Pulses: 1 Gate start: 0.1 Gate width: 0.5

23 Phased Array Theoretical Resolution Lateral (X): ΔD = (0.44 x V) / (F x sin (θ/2)) Axial(Z): ΔZ = V x T/2 Elevation(Y): Defined by the length of the array elements, and will be on the order of several millimeters Source: Olympus NDT Manual 23

24 Resolution Summary INSPECTION SYSTEM AXIAL RESOLUTION LATERAL RESOLUTION ELEVATION RESOLUTION Acoustocam 1.5 mm 0.1 mm 0.1 mm PAUT 0.3 mm 0.34 mm > 1.0 mm

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29 Acoustocam Omniscan: Amplitude Omniscan: TOF

30 Comparative Study: Acoustocam, X-ray, Phased Array Reviewed different techniques for corrosion mapping Used common standards Recorded image quality Recorded time of setup, scan, training cost

31 Stepped standard Targets Studied Corrosion piece 8 diameter pipe section

32 Stepped Standard Acoustocam Phased Array X-ray 192 iridium

33 0.25 Corroded Steel Panel Acoustocam Phased Array X-ray 192 iridium

34 Acoustocam 8 Diameter Pipe Section Phased Array X-ray 192 iridium

35 Total Cost of Ownership Training Setup time Equipment cost Lost opportunity

36 Corrosion Mapping Comparison NDT Method FirstMap Phased Array with Scanner Iridium-192 Radiography Daily Cost ~$800 ~$1200 ~$2000 Inspection time per square foot (includes setup) Required Training 5 minutes 15 minutes 30 minutes 16 hours 160 hours 400 hours Required Experience Level I or Level II Level II NDT Advanced Availability of Technicians Required Technicians Available Limited Very limited

37 What Goes Up Must Come Down POD due to 100% coverage and higher resolution Productivity Profits Morale Training Cost Down time Turn around/shut down time Lost opportunity time doing more with less

38 ANA Airlines This instrument is quite helpful for catching the image of internal structures and detecting the delamination quickly with C-scan mode. Imperium s Camera is easy to set up and handle. Therefore, our NDT inspectors prefer to use the Imperium camera. Moreover, it is capable of remote usage by line mechanics at local airports. Consequently, ANA would like to use the Imperium Camera in the future and for remote inspection. Hiroshi Kobayashi ANA Senior Manager Structural Engineering

39 New Scanner Under Development With Angle Beam Adjustment 39

40 Imperium, Inc F Ammendale Rd Beltsville, Maryland / fax 40