Quasi-Model Development using Digital and Non-destructive Inspection Data

ABSTRACT: TRI/Austin will develop a method for generating 3D digital models of aircraft components and structures by piggybacking on data from commonly used in-service depot inspections. Modern cost saving programs, such as Condition Based Maintenance Plus (CBM+) and High Velocity Maintenance (HVM), developed and implemented throughout the Air Force, rely on digital data flows and analyses. Unfortunately, older mission critical aircraft, such as the B-52 and C-130, were designed before the advent of the digital era. TRI/Austin proposes to use its NDI modeling and experimental expertise to develop techniques, algorithms, and software to generate digital 3D models of aircraft parts using data from one-sided inspection techniques. Unlike current methods for reverse engineering aircraft parts to generate 3D models, which require their removal from the aircraft, these one-sided inspections techniques do not and can be performed in tandem or in parallel with existing inspections performed in the depot environment. Data from multiple inspections and multiple inspection techniques will be correlated to refine the digital models. Software with a simple interface will display all correlated data and 3D model renderings. The generated surface mesh will be output in common file formats so that they may be used with other existing software packages.; BENEFIT: Having a digital twin for components and structures is needed in manufacturing, as well as at repair facilities, to preserve the digital thread. The total market associated with solely imaging unknown structures is probably on the order of < 10 systems, based on the number of facilities where the repair of aging aircraft is expected to occur. Being able to apply this technique to new production is key to developing a commercially viable product. It is envisioned that this method for 3D part modeling using NDI data would be integrated into TRI/Austins NDEToolbox software system, and could easily be deployed to support the management of weapon systems by the specific Program Offices. The NDEToolbox has potential customers outside of defense which utilize nondestructive inspections. These include oil and gas, automotive, structural maintenance, etc. The F-35, the KC-46, and the next generation bomber are the largest programs underway at the Air Force for new aircraft. Each of these program offices are a potential customer for the outcomes of this program, as new designs drive down structural factors of safety and increase the need for accurate digital twins. These are just a couple of TRI/Austins long term opportunities to provide the product developed for this solicitation.