aircraft_inspection

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®YXLON.Aircraft InspectionYXLON.InternationalGERMANYYXLON International X-Ray GmbH*Essener Bogen 15D-22419 Hamburg GermanyT: +49 40 527 29-0F: +49 40 527 29-170E-mail: yxlon@ YXLON CT Development GmbH*Am Walzwerk 41D-45527 Hattingen GermanyT: +49 2324 5629-0F: +49 2324 5629-29E-mail: yxlon@ YXLON International Feinfocus GmbH*Im Bahlbrink 11-13 D-30827Garbsen GermanyT:+4951317098-0F:+4951317098-80E-mail:yxlon@ DENMARKYXLON International AS*Helgeshøj Allé 38DK-2630 Taastrup DenmarkT: +45 72 40 77 00F: +45 72 40 77 01E-mail: yxlon@ USAYXLON International Inc.*3400 Gilchrist Road Akron, OH 4420-1221USAT: +1 330 798 4800F: +1 330 784 9854E-mail: yxlon@ YXLON International Inc.*San Jose Branch2342 Bering Drive San Jose, CA 95131USAT: +1 408 325 8770F: +1 408 325 8773JAPANYXLON International KK*JK Ohmori Bldg., 28-10,Minami Oi 3-chome,Shinagawa-ku Tokyo, 140-0013JapanT: +81 3 5753 6021F: +81 3 5753 6024E-mail: yxlon@ www.yxlon.co.jpCHINAYXLON International X-Ray GmbH*Shanghai Rep. OfficeNo. 333, Cheng Du Road (N) Room 701,South Block, China Merchants Plaza, Shanghai 200041PR ChinaT: + 86 21 6218 5349F: + 86 21 5298 1572E-mail: qinv@ YXLON International X-Ray GmbH*Beijing Rep. OfficeC1809 Web Times Center 17 Zhongguancun South Ave.HaidianBeijing 100081PR ChinaT: + 86 10 8857 9581F: + 86 10 8857 9580E-mail: wangjs@ * a company of the COMET GroupYXLON.Aircraft InspectionStrict quality controls during production and maintenance are a prerequisite for ful -filling the high safety standards that prevail in the aviation and aerospace industry.X-ray inspection has been a ‘tried-and-true’ method in implementing those controls for years. It can be used to detect the tiniest flaws along welded pipe seams, in turbine blades or parts made of fiber-reinforced composites, and without destroying these high-grade inspection items. Through the use of computed tomography (CT),which is equally based on X-ray technology, it is also possible to analyze inner struc-tures, e.g. those of turbine blades, and to compare such structures with CAD data.The diverse areas of deployment with their respectively unique features place high demands on the X-ray inspection or CT systems to be utilized.Solutions to match any requirementYXLON offers the fitting solution to match each and every need. Our product spec-trum includes fully radiation-shielded cabinets with various manipulation systems,yet also manipulation systems for large-scale parts and portable X-ray inspection systems for use in the field, too. Above and beyond that we offer a large selection of CT systems for the widest variety of applications. For all of our systems, the use of high-grade components combined with high-performance analysis software enable us to provide you with an assured inspection decision while offering a high degree of user friendliness at the same time. The range of our product portfolio guarantees that we can offer you precisely the solution to match your requirements.High-quality solutions for the non-destructivetesting of aircraft componentsA large number of bleed air ducts, con-duits and tubing systems are built into aircraft. Due to the geometric structures which result in the course of production assembly, some of which are highly complex, these systems are marked by a large number of welding joints. Those joints are exposed to high levels of mechanical and thermal stress simul -taneously in the course of use. That's why the quality of welding joints must be very high. The testing of that quality is regulated in norms and detailed guide-lines specified by aircraft manufacturers.X-ray inspection permits an assured detection of welding flaws within the process involved. That's why this method has been successfully employed toward quality control for years. Film had been mainly used as the imaging medium until now.Modern welding -seam inspectionfor even greater safetyThe use of modern, digital flat-panel detectors can increase inspection assur-ance with respect to defect recognition even further. For instance, using YXLON software a leading aircraft manufacturer verified that flaws in circumferential welding seams are detected with a greater probability than with conven-tional film technology. This is already managed without any follow-up editing of the digital image. Further enhance-ments can be achieved using functions from YXLON image processing software.The use of digital technology offers even more advantages. The inspection cycle time is substantially reduced, and the use of chemicals which had been necessary until now, including their subsequent costs such as pollutant waste disposal, no longer applies.Operating temperatures in jet aircraft engines are being increased constantly in order to raise the degree of efficiency.That results in cooling mechanisms for turbine blades which are becoming more and more complex.Defects that occur during production such as boring into the rear wall or the existence of foreign substances in the cooling channels can be detected using X-ray inspection. In the case of turbine blade maintenance, X-ray technology allows the inspection of material which has been welded onto blade leading and trailing edges.The use of digital detectors is advanta-geous for both applications because the large number of gradations on their gray scales enables the analysis of radioscopic images displaying large differences in material thicknesses.Inspection of turbine blades inproduction and maintenanceWhen producing turbine blades, the wall strengths between the cooling channels and the outer wall can turn out to be too thin. The same can happen between the individual cooling channels.Particularly when other quality-control procedures do not provide findings with any certainty due to the presence of inner walls or turbulators, the advan-tages of computed tomography (CT)come to bear: It enables a no-contact,reproducible measurement of all struc-tures with a high degree of accuracy. In addition, a reverse engineering of these complex products can also be conducted by generating CAD data from the volu-metric model created.The YXLON method of CT measurement permits an exact quality statement to be made, even for strict approval regu-lations.Independent of the casting process involved, metallic aircraft components must be tested for material flaws on a non-destructive basis after they have been shaped. A 100 % inspection using X-rays is stipulated for many casted parts to accomplish this. Besides that,the scale geometries specified by the customer must also be enacted, and an inspection decision according to speci-fications must be made possible. When film is used as the imaging medium, the inspection process for several casted parts with complex shapes, e.g. the guide vanes used in jet aircraft engines, can take several days.The use of digital technology combined with YXLON advanced image processing software allows enormous time-saving potentials to be realized, and thus money as well.Wide-ranging options for using radioscopyAircraft parts with large surface areas are frequently manufactured in a honey -comb structure to fulfill the requirements for low weight and simultaneously high stability. In this case, retaining the in-tegrity of the honeycomb shape during the production process is just as impor -tant as the proper adhesion free of pores between the surface material and the honeycomb itself.Our tests have shown that here too X-ray inspection presents an assured and rapid method for quality assurance.Depending on the respective inspection criteria involved, image intensifiers or digital flat-panel detectors find use as the imaging media. Above and beyond them, our high-quality image processing software contributes to inspection results that are reproducible and offer certainty.As a result of their high, weight-specific tensile strengths and rigidities, fiber-reinforced composites made of carbon are being seen more frequently in inno-vative aircraft construction. Their use is resulting in completely new challenges for quality assurance.Delaminations can occur, and small gas voids (porosities) can form during the fabrication process even with the usage of vacuum forming technologies. Foreign substances in the composite must also be found before the material is utilized.Alongside non-destructive inspection processes such as ultrasonics, testing with X-rays also leads to very good results here. In addition, no drying of the inspection items is necessary follow -ing X-ray inspection.New challenges for qualityassurance through new materialsX-ray technology makes it possible to depict structures with only slight differ -ences in material thickness through the use of special flat-panel detectors and X-ray tubes that are adapted to the unique features of carbon fiber-reinforced composites. Porosities in the adhesive are made highly visible thereby.X-ray inspection additionally enables a relatively large segment of the inspection item to be tested in one step. Foreign substances that cover an extensive area and were accidentally cast in during production are made identifiable thereby.Yet another significant advantage is that X-ray inspection is the only non-destruc-tive method that enables a statement to be made regarding the correct posi-tion of individual fibers.The Y.Multiplex family is a series of technologically and qualitatively high-grade X-ray inspection systems that can be adapted flexibly to match customers' needs.Inspection envelopes in various sizes enable quality assurance for the widest variety of inspection items and materials. Intelligent manipulation systems, state-of-the-art system technology and an ergonomic operating concept ease the burden on the operator. The inspection task itself is placed in the foreground while enabling an inspection decision with certainty.Y.Multiplex XL and XXLThe specifications for inspecting the welding seams of bleed air ducts with complex shapes were implemented in the Y.Multiplex XL and XXL especially to meet the needs of the aviation industry. From the X-ray tube to a digital flat-panel detector and on to the software for analyzing and archiving the images, the image chain fulfills the demands posed on a substitute for film.Operation takes place via a central operating console. It has been set up on a modular basis and can be configured with respect to the number of monitors, the width of the work area and the overall height. Great importance was attached to the ergo-nomic arrangement of the operating elements during development.A series of inspection positions can be programmed very easily using an intuitive graphic user interface. The program can be interrupted at any time in order to investigate suspicious areas of the inspected item manually.Y.Multiplex – Modular setupto meet the highest standardsModular setup of the Y.Multiplex familyMU 2000 RobotMU 2000 Robot has distinctly increased the effectiveness in inspecting turbine blades. MU 2000 Robot is based on a proven standard cabinet into which a multi-axis robot has been integrated. As just one example, it is suitable for inspection tasks which deal with deciding whether sufficient original material remains on turbine blades so that weld-ons of additional material can be carried out.The operator enters the model or series designation of the turbine blades to be inspected via the graphic user interface on the operating console. The cabinet is then loaded manually using a pallet on which the corresponding blades lie. The robot selects the appropriate grabber, grabs hold of the blade and travels along the programmed positions. The production item is thus X-rayed and measured at various positions.Generating a low-noise radioscopic image of the turbine blade is decisive in order to meet the high standards set by the inspection task. Modern digital flat-panel detectors with a high range of gray-scale dynamics are therefore used in MU 2000Robot. That enables all of a blade's material thicknesses to be depicted clearly.Turbine blade measurement takes place manually and is supported by the automatic detection of rising and falling pitches in the tool that measures the gray scale's line profile.Robot-supported inspectionof turbine bladesTurbine blade inspection using MU 2000 RobotY.Access 100The Y.Access ceiling mount is a universally deployable solution for inspecting large parts via X-rays. Flexible adaptation to the inspected items' dimensions enables the testing of wing elements, ailerons, flaps or other large and bulky parts.Y.Access 100 is mounted on the ceiling of an X-raying room.The possibilities for loading the room are not restricted thereby because both the X-ray tube and detector unit can be retracted all the way to the top. Y.Access 100 can be equipped with the ideal imaging chain to suit the respective requirements. For instance, all YXLON X-ray tubes from 160kV to 225kV and 320kV to 450kV can be integrated into the system. The same applies for image intensifiers or flat-panel detectors. The focus-to-detector distance (FDD) is variable, and the beam's course can be tilted. Potential post-oscillation is minimized through the concept of four broad bands.The system is operated via joystick or a computer-guided operational control.Flexible solutions forthe widest variety of demandsY.MaxishotWith Y.Maxishot YXLON is offering a simple and compact fully radiation-shielded cabinet for the most diverse areas of deployment. It is particularly suited for testing smaller and less complex items which do not have to be moved during inspection. In the standard model, Y.Maxishot is optionally equipped with either a 160 kV, 225 kV or 320 kV X-ray tube.The low-level complexity of its design makes the system equally well suited for film exposures and for radioscopic images using flat-panel detectors. The use of a flat-panel detector as the imaging medium presents Y.Maxishot as a point of entry into the world of digital X-ray technology. Its orientation is aligned on the one hand very closely to that of conventional film technology processes, thus requiring few changes in the course of inspection operation. On the other,benefits such as the avoidance of chemicals for developing film can already be taken advantage of.Y.Maxishot can be modified upon customer request to adapt to the size of inspection items. Additional fittings with a turn -table or an X-Y table for simple parts manipulation is also possible.Portable and mobile X-ray systems from YXLON have been conceived especially for flexible on-site use – in maintenance for example – and distinguish themselves equally through their high reliability and easy-to-use operation.Y.XPO and Y.SMARTTheir low weight and compact dimensions make the portable X-ray systems Y.XPO and Y.SMART excellently suitable for use in aircraft maintenance. The systems ex-hibit low power consumption and are resistant to voltage fluctuations. Alongside functionality, a high degree of robustness was a focus in selecting the materials used in order to ensure trouble-free use, even under difficult conditions. YXLON offers units ranging from 160 kV to 225 kV to 300 kV.Y .XMBThe compact, constant potential X-ray systems Y.MXB 160 and Y.MXB 225 are especially well suited for assignments where a high dosage output is required in addition to flexibility and mobility. In combination with the wide selection of uni-polar metal-ceramic X-ray sources offered by YXLON, flexible X-ray systems arise for nearly any mobile application. All of the systems' components are mounted on a handtruck equipped with pneumatic tires, a crane hook and two tipping axes,and can thus be easily moved by one person to the site of use.Portable and mobile solutionsfor on-site useY.XPO 225 for on-site useYXLON CT systems were developed to support your development and production processes. They can provide information about inner structures, mechanical behavior and the dependability of production quality. Specially developed, high-grade line detectors produce high-resolution cross-sectional images of a certain layer or a volumetric depiction of the entire inspection item. YXLON offers both standard systems and customer-specific solutions.YXLON was the first company to produce a working system for the fully automated inspection of turbine blades.The system's robot takes the turbine blades from a conveyor belt and places them on the CT manipulator. Cross-sectional CT images of the continuously rotating turbine blade are created during the subsequent inspection run. Laser bores located too close to each other as well as bores which are drilled too deep are automatically detected by means of the cross-sectional images. When a penetration of the inte-rior wall like that has occurred, the software measures the remaining wall thick ness.All inspection results are documented and clearly categorized by means of the previously scanned series number. Comprehensive measurement of the turbine's cross-sectional image is also possible in order to determine the minimum or maximum wall thicknesses within previously defined polygons.Y.CT Solutions – CT systemsto meet the highest standardsFully automated inspection of turbine bladesYXLON.Solutionsponentsgradiations.Depiction of the gray values can be conve niently set using the combined brightness and contrast er-defined settings can be saved thereby and retrieved quickly via mouse click as needed.Immediate detection of even the tiniest flaws in inspection items exhibiting the widest variety of material thicknesses is made possible through the use of the various image process-ing filters in the Y.Image x500 family. Further key elements in the x500 software family are functions toward the qualifi-cation of image quality: They enable an objective inspection decision. The semi-automated determination of geometric resolution with image quality identifiers in compliance with EN 461-5 is possible just as easily as the determination of hole detectability with image quality identifiers under the observance of contrast resolution in compliance with ASTM E 1025 or ASTM E 1742. A menu item guides the operator through the evaluation and documentation of these system parameters, e.g. in order to implement a regular control of image quality at the beginning of a shift. Y.Image x500 saves images in the standardized multi-TIFF format in order to meet the highest safety standards.High-quality image processing foran inspection decision with certaintyThe good results supplied by our inspection systems are based not least of all on the use of high-quality components from state-of-the-art technology combined with high-performance image processing software.Y.Image x500 software familyThe high-quality image processing and image storage systems from the Y.Image x500 family help to make inspection deci-sions with certainty. Software functions like the adjustable magnifying glass, detail enlargement without sawtooth distor -tions or gray-value optimization using one mouse click make even small flaws clearly visible in radiographic images display -ing an area with very different material thicknesses. The result is a substantially more efficient analysis of the image than would occur using a conventional film viewer. The systems within the Y.Image x500 family can be deployed to the same degree using image intensifiers and flat-panel detectors.The Y.Image x500 family has special calibration functions for use with flat-panel detectors that enable a better image quality than is possible using film. The signal-to-noise ratio is optimized and the entire gray-value zone supported by up to 65,535。