Analysis of a structure modeled with inconsistencies mapped thereon

A method of analyzing a structure including at least one inconsistency, the method comprising:

• processing nondestructive inspection (NDI) data for the structure composed of a plurality of layers, the NDI data being processed to define an area of inconsistency at an internal layer of the plurality of layers, or an interface between a particular pair of adjacent layers in the plurality of layers;
• receiving a finite element model of the structure in which the structure does not include any inconsistency, the finite element model being composed of a plurality of finite elements having respective element datasets, the plurality of finite elements including a mesh of finite elements for each of the plurality of layers, and finite elements at an interface between each pair of adjacent layers in the plurality of layers;
• mapping the area of inconsistency to at least some of the plurality of finite elements that are thereby identified as affected finite elements, and that include finite elements of the mesh of finite elements for the internal layer, or the finite elements at the interface between the particular pair of adjacent layers;
• producing a reconstructed finite element model of the structure from the finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements;
• and
• performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, the FEM failure analysis producing an output that indicates an extent of residual integrity of the structure,
• wherein the NDI data includes a plurality of data points having respective three-dimensional positions within a coordinate system of the structure, and processing the NDI data comprises:
• converting data points of the plurality of data points to corresponding data points having respective two-dimensional positions at the internal layer or the interface between the particular pair of adjacent layers;
• and
• calculating an outer boundary of the corresponding data points to determine the two-dimensional boundary of and thereby define the area of inconsistency at the internal layer or the interface between the particular pair of adjacent layers.

A computer-readable storage medium for analyzing a structure including at least one inconsistency, the computer-readable storage medium being non-transitory and having computer-readable program code portions stored therein that in response to execution by a processor, cause an apparatus to at least:

• process NDI data for the structure composed of a plurality of layers, the NDI data being processed to define an area of inconsistency at an internal layer of the plurality of layers, or an interface between a particular pair of adjacent layers in the plurality of layers;
• receive a finite element model of the structure in which the structure does not include any inconsistency, the finite element model being composed of a plurality of finite elements having respective element datasets, the plurality of finite elements including a mesh of finite elements for each of the plurality of layers, and finite elements at an interface between each pair of adjacent layers in the plurality of layers;
• map the area of inconsistency to at least some of the plurality of finite elements that are thereby identified as affected finite elements, and that include finite elements of the mesh of finite elements for the internal layer, or the finite elements at the interface between the particular pair of adjacent layers;
• produce a reconstructed finite element model of the structure from the finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements;
• and
• perform a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, the FEM failure analysis producing an output that indicates an extent of residual integrity of the structure,
• wherein the NDI data includes a plurality of data points having respective three-dimensional positions within a coordinate system of the structure, and the apparatus being caused to process the NDI data includes being caused to:
• convert data points of the plurality of data points to corresponding data points having respective two-dimensional positions at the internal layer or the interface between the particular pair of adjacent layers;
• and
• calculate an outer boundary of the corresponding data points to determine the two-dimensional boundary of and thereby define the area of inconsistency at the internal layer or the interface between the particular pair of adjacent layers.