Phased array ultrasonic bolt inspection apparatus and method

An ultrasonic non-destructive evaluation (NDE) inspection system for a fastening bolt, comprising:

• a bolt inspection apparatus, having:
• a bolt holding fixture adapted for coupling to an end of a bolt about the bolt circumference, for retaining the bolt during an ultrasonic inspection;
• a transducer plate rotatively mounted on the holding fixture, having an axis of rotation aligned with an axial centerline of a bolt coupled to the holding fixture;
• and
• a phased array ultrasound probe coupled to the transducer plate, having a scanning axis intersecting the bolt circumference when the bolt is coupled to the holding fixture, the probe generating bolt inspection scan data;
• a rotational position encoder coupled to the transducer plate, for generating transducer plate rotation position data;
• an ultrasound analyzer coupled to the phased array probe for receiving scan from the probe and generating inspection data for identifying possible defects in an inspected bolt end that is coupled to the holding fixture;
• and
• a controller coupled to the rotational position encoder and the ultrasound analyzer, for receiving and correlating rotation position data and inspection data, in order to identify location and characteristics of possible defects in the inspected bolt end.

A method for non-destructive evaluation of an end of a fastening bolt, comprising:

• providing an ultrasonic non-destructive evaluation (NDE) inspection system for a fastening bolt, comprising:
• a bolt inspection apparatus, having:
• a bolt holding fixture adapted for coupling to an end of a bolt about the bolt circumference, for retaining the bolt during an ultrasonic inspection;
• a transducer plate rotatively mounted on the holding fixture, having an axis of rotation aligned with an axial centerline of a bolt coupled to the holding fixture;
• and
• a phased array ultrasound probe coupled to the transducer plate, having a scanning axis intersecting the bolt circumference when the bolt is coupled to the holding fixture, the probe generating bolt inspection scan data;
• a rotational position encoder coupled to the transducer plate, for generating transducer plate rotation position data;
• an ultrasound analyzer coupled to the phased array probe for receiving scan from the probe and generating inspection analysis data for identifying possible defects in an inspected bolt end that is coupled to the holding fixture;
• and
• a controller coupled to the rotational position encoder and the ultrasound analyzer, for receiving and correlating rotation position data and inspection data, in order to identify location and characteristics of possible defects in the inspected bolt end;
• inserting and coupling an end of a bolt into the bolt holding fixture;
• rotating the transducer plate, while obtaining bolt inspection scan data with the probe and position data with the rotational position encoder;
• generating inspection analysis data derived from the inspection scan data with the ultrasound analyzer;
• identifying location and characteristics of possible defects in the inspected bolt end, derived from the inspection analysis data and the position data with the controller.