Due to improvements in the Ultra Image IV automated scanners, the AANC at Sandia National Laboratories purchased an Ultra Image IV scanner in late 1994 for their own in-house use. The US Air Force has purchased prototype systems for use on the C-141 aircraft which are being used in a validation program, in the the lab, on aircraft, as well as, in a probability-of-detection (POD) experiment to validate the detection of second-layer fatigue cracks in spanwise splice. The inspection process being implemented dramatically lowers an estimated $150M fleet inspection to less that $15M. The systems are equipped with automated scanners that feature full X-Y control, couplant supply, constant force probe control, and vacuum attachment to the part under inspection. The scanners can be used in all orientations on the aircraft.

The new scanners are designed with improved load capacity that can accomodate a transducer head carrying one to three transducers in pulse/echo and pitch/catch modes. The new scanners are driven by AC servo motors and weigh 40 pounds (6-by-36 inch scan envelope, typically). Scanners can be customized with different scan envelopes to cover lengths from 24-48 inches and widths from 6-24 inches. X-Y scan resolutions of 0.010 inches are routine. The scanners are outfitted with limit switchs and emergency stops for collision avoidance and include a low-vacuum alarm for the suction cups. Improvements have been made in the probe holder and gimbal design to glide over surface irregularities. The utility services case provides air, couplant, and vacuum services for the scanner. The computer contains a Pentium 133 MHz processor, hard disk, an Iomega JAZ drive, and a 3.5-inch floppy drive. The ultrasonic system runs under IRT ScanMaster software and operates up to eight channels, up to 32 gates per channel, with full A-, B-, and C-scan capability. Image processing and analysis include pan & scroll, flaw-sizing, zoom, editable color palette, histogram, 3-D views, image enhancement, screen annotations and screen image capture in exportable display format. Software is available for life-cycle monitoring of part integrity, computerized flaw search, angle correction for oblique incidence wave, and Fourier-transformed B and C-scan imaging. Operator training can be accomplished in two days by a Level II ultrasonic technician.