Acknowledgments. 1.1 Introduction Metals Aluminum from Planes to Cars Composites Black Metal Summary 13 Reference 15

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1 contents Preface Acknowledgments xiii xvi Noncontact Ring-Laser Metrology Systems CHAPTER 1 Introduction Introduction Metals Aluminum from Planes to Cars Composites Black Metal Summary 13 Reference 15 CHAPTER 2 System Components Introduction Optical Probe Camera Probe-Camera Assembly Machine Vision Software Package Hole-Bore Location Guidance System Summary 30 CHAPTER 3 Operation Introduction Measurement Capabilities Diagnostics Capabilities 34 vii

2 viii Contents 3.4 Analytics Capabilities Composite Capabilities Speed and Repeatability Capabilities Strategic Impact Utility Composite Applications Tactical Impact Uncollected In-process Costs Improving Design Explanation of Automated Gauge Operation The Basics Gauge Integration and Operation Explanation of Handheld Gauge Operation The De-stack Solution Summary 49 CHAPTER 4 Application Introduction Familiarity Overcoming the Norm How Much Is Too Much? Current Processes Hand Drill Hole-Bores Using an Air Operated Drill Motor with Multiple Drill Bits in Progressive Steps, Countersink, Clean, and Measure Mechanized Drilling Using Power Feed Motors to Drill Hole-Bores with Multiple Drill Bits in Progressive Steps, Countersink, Clean, and Measure On-assembly Automated Drilling, or Drilling and Countersinking Using a Numeric Controlled Precision Drill and Countersinking End Effector Application with Replication Hand Drill/Countersink Gauging Mechanized Drill/Countersink Gauging 60

3 Contents ix Automated Drill/Countersink Gauging Combined Operation Teaming Application Application Strategy Summary 62 References 63 CHAPTER 5 Extensibility Introduction From the 60s to Late 70s Late 70s to Late 80s Late 80s to Late 90s Late 90s to Late 2000s Today Competitive Alternatives Gauges Features Shortcomings Other Emerging Technologies Capacitive Sensing Confocal Sensing Summary of Single Noncontact Gauging Solution Extensibility Market Size Addressable Market Gauge/Measurement Tool Investment Manual Gauge Analysis (Current Operating Model) Single-Gauge Replacement (Aeroscan Type) Analysis Industry Analysis Total Projections Replacing Current Manual Gauges Incorporating into Automated (Replace Manual) MRO In Service Tooling Training 81 Reference 81

4 x Contents CHAPTER 6 Summary Introduction Capabilities Measurement Capabilities Diagnostics Capabilities Analytics Capabilities Composite Capabilities Speed and Repeatability Capabilities Multiple Hole-Bore Size Capabilities Components Optical Probe Machine Vision Software Package Hole-Bore Location Guidance System Field Calibration Methods Back-End Solution Why This Gauge Is a Noninvasive and Disruptive Technology Strategic Impact Utility Composite Applications Tactical Impact Costs of Airframe Manufacturing, Uncollected In-process Costs Summary 95 References: Applicable Gauge Patents 96 Nondestructive Adhesive Bond-Line Inspection CHAPTER 7 Introduction Introduction Models to Machines Complexities of Adhesives Black Metal to Black Gold 106

5 Contents xi Unified Structure Adhesive Bonding Z-Pins Technology Solution Summary 112 References 113 CHAPTER 8 Application Introduction Composite Bonding Definitions Co-curing Co-bonding Adhesive Bonding (Secondary Bonding) Metal Bonding Adhesive Bond Function Theory Basic Bonding Requirements Bond Strength and Durability Understanding Bond Failures Identification of Adhesive Bond Failures Adhesion Failures Failure of Composite Bonds Summary: Substantiation of Structural Integrity 125 References 128 CHAPTER 9 Operation Introduction Laser-Generated Stress Waves Laser Bond Inspection Development Laser Bond Inspection Test Results Laser Bond Inspection System Summary 146

6 xii Contents Acknowledgment 146 References 146 CHAPTER 10 Extensibility Introduction Composite Bonding Definitions Co-curing Co-bonding Adhesive Bonding (Secondary Bonding) Metal Bonding Types of Bond-Lines Complementary Technologies Case Study: Wide-Area Inspection Bond-Line Deficiency Discovery and Mitigation Summary 158 Additional Reading 159 References 159 CHAPTER 11 Summary Introduction Adding Complexity Repair Repair During Manufacture Repair Operational Damage Maintenance Safety Summary 170 References 171 CHAPTER 11 Closing Words Technology Evolution 173 Additional Reading 179