BR112021001519B1 - METHOD OF FORMING A WEAR SOLE STRUCTURE FOR AN ULTRASONIC INSPECTION DEVICE - Google Patents

Abstract

''WEAR SOLE FOR ULTRASONIC INSPECTION AND METHOD OF MANUFACTURING''. The present invention relates to a method for forming a wear sole that includes forming a plurality of layers from a structure material, adjacent layers bonded together to define a structure. The structure may include a proximal surface configured to secure the structure in a probe socket, a distal surface configured to contact a portion of a target, a body extending between proximal and distal surfaces, an aperture extending through the proximal and distal surfaces and the body, and a channel extending from the proximal surface to a chamber in fluid communication with the distal surface. The method may optionally include placing a membrane within the aperture. The membrane may be coupled to the body by a seal, which inhibits the passage of a fluid through the proximal surface via the aperture. The chamber may extend within the body between a distal surface of the membrane and the distal surface of the structure.

Description

BACKGROUND

[001] Ultrasonic inspection can be used to detect defects (e.g., cracks, inclusions, voids, etc.) in a non-destructive manner in manufactured articles such as tubes, bars, bundles, ingots, or other parts that require non-destructive inspection. As an example, an ultrasonic transducer can be used to transmit ultrasonic waves (sound waves) to the inspected part, and these transmitted ultrasonic waves can be reflected from boundaries within the inspected part (e.g., defects and external boundaries) back to the ultrasonic transducer. The properties of the reflected ultrasonic waves can be measured by the ultrasonic transducer and subsequently analyzed to identify characteristics of defects detected within the inspected part, which include location and size.

[002] During inspection, ultrasonic transducers may be distanced from the inspected part to prevent wear and dirt buildup. Because ultrasonic waves are not transmitted effectively through air at the ultrasonic frequencies used in nondestructive testing, an ultrasonic couplant (e.g., a liquid or gel) is typically provided within a space between the transducer and the inspected part to facilitate transmission. When the ultrasonic transducer is moved to a new location, the ultrasonic couplant drains from this space and is replenished before inspection continues. Although the delay incurred due to individual loading is relatively modest (e.g., about 5 s), it can add hours in a high-throughput inspected part manufacturing environment where hundreds to thousands of tubes are tested daily.

SUMMARY

[003] In general, systems and methods are provided for ultrasonic testing of manufacturing wear materials and components for a nondestructive ultrasonic inspection system.

[004] In one embodiment, a probe fitting configured to receive an ultrasonic probe is provided and may include a body, a wear sole, and a fluid channel. The body may define a first chamber configured to receive a first volume of ultrasonic couplant. In certain embodiments, the first chamber may also be configured to receive a distal end of an ultrasonic probe. The wear sole may define a second chamber configured to receive a second volume of ultrasonic couplant and may be removably coupled to a distal end of the body. The wear sole may also have a membrane extending therethrough to separate the first chamber from the second chamber. The fluid channel may extend through the body and the wear sole, and may be configured to deliver the second volume of ultrasonic couplant to the second chamber.

[005] The wear sole may have a variety of configurations. In one embodiment, the wear sole may include an aperture extending between a proximal facing surface and a distal facing surface, and the membrane may be positioned within the aperture. In certain aspects, the membrane may be configured to propagate ultrasonic waves therethrough.

[006] The second chamber may have a variety of configurations. In one embodiment, at least a portion of the second chamber may be aligned with the first chamber. In certain aspects, a volume of the second chamber may be smaller than a volume of the first chamber.

[007] In another embodiment, a distal side of the wear sole may be configured to correspond to a tube.

[008] In another embodiment, the wear sole may include a lateral tab and the body may include a slot formed laterally adjacent the distal end. The slot may be configured to receive the lateral tab.

[009] In another embodiment, an ultrasonic inspection wear sole is provided and may include a structure configured to removably mate with a probe fitting body. The structure may have an aperture extending therethrough between a proximal facing surface and a distal facing surface. A membrane may extend across the aperture and may be configured to propagate ultrasonic waves therethrough. The structure may also have a fluid delivery channel formed therein for delivering an ultrasonic couplant to a portion of the distal aperture in the membrane.

[0010] The structure may have a variety of configurations. In one embodiment, the structure may include a side tab configured to engage a corresponding slot in the probe fitting body. In certain aspects, a distal facing surface of the structure may be configured to mate with a tube. In another aspect, the structure may be configured to direct ultrasonic couplant flow along at least a portion of the length of the membrane.

[0011] In another embodiment, the membrane may be displaced proximally from the distal facing surface of the structure.

[0012] In another embodiment, the fluid delivery channel may be configured to direct a flow of ultrasonic couplant from a first side of the structure to a second side of the structure opposite the first side of the structure.

[0013] In another embodiment, an ultrasonic inspection method is provided and may include removably coupling a wear sole to a distal end of a probe fitting, positioning the probe fitting in contact with a pipe via the wear sole, loading a first chamber in the probe fitting with a first volume of ultrasonic couplant, and loading a second chamber extending between the wear sole and the pipe with a second volume of ultrasonic couplant. The first and second chambers may be separated by a membrane, and the second volume of ultrasonic couplant may be in fluid contact with the pipe. The method may further include propagating ultrasonic waves from an ultrasonic transducer in the probe fitting, through the first volume of ultrasonic couplant, through the membrane, and through the second volume of ultrasonic couplant to the pipe.

[0014] In another embodiment, the membrane may extend through an opening in a structure of the wear sole, and the method may further include removing and replacing the wear sole with a new wear sole having a membrane extending therethrough to separate the first and second chambers.

[0015] In another embodiment, the first volume of ultrasonic couplant in the first chamber may be greater than the second volume of ultrasonic couplant in the second chamber.

[0016] In other aspects, the first volume of ultrasonic couplant in the first chamber may remain substantially constant and the second volume of ultrasonic couplant may be continuously delivered to the second chamber to charge the second chamber.

[0017] In another embodiment, the second volume of ultrasonic couplant may be delivered to the second chamber via a fluid channel extending through the probe fitting and the wear sole.

[0018] In another embodiment, the membrane may be configured to propagate ultrasonic waves emitted by the ultrasonic probe.

[0019] As discussed herein, ultrasonic inspection systems may include an ultrasonic transducer, a wear sole, a probe fitting, and a coupling means. The wear sole may be configured to be readily removable and exchangeable from the probe fitting, which enables the wear sole to be replaced during inspection when a degree of wear exceeds a threshold amount. Embodiments of the present disclosure provide for fabrication of wear soles in a layer-by-layer manner using additive manufacturing techniques, also referred to as 3D printing. Wear soles fabricated in this manner may exhibit one or more specific suitable properties, such as wear resistance, acoustic properties, fluidic properties, reduced weight and/or increased stiffness, prevention of couplant bubbles, clearance of existing couplant bubbles, and fast coupling times.

[0020] In certain embodiments the layers of the wear sole may be configured to provide gradients in their acoustic properties. The acoustic properties may include, but are not limited to, one or more of velocity, attenuation, and impedance. As discussed in detail below, by fabricating the wear sole with different regions having different acoustic properties, the ultrasonic energy traveling through the wear sole may be controlled so as to avoid unwanted reflections. The different regions may include one or more of cavities, wedges, and different densities.

[0021] In one embodiment, a method for forming a wear sole of an ultrasonic testing device is provided. The method may include forming a plurality of layers from at least one frame material, wherein adjacent layers of the plurality of layers may be bonded to one another to define a structure of a wear sole. The structure may include a proximal surface, a distal surface, a frame body, an aperture, and a channel. The proximal surface may be configured to secure the structure to a distal end of a probe fitting. The distal surface may be configured to contact a portion of a target surface. The frame body may extend between the proximal and distal surfaces. The aperture may extend through the proximal surface, the frame body, and the distal surface. The channel may extend from the proximal surface to a chamber in fluid communication with the distal surface.

[0022] In another embodiment, the method may include placing a membrane within the aperture, adjacent the proximal surface. The membrane may be coupled to the frame body by a substantially fluid-tight seal so as to inhibit the passage of a fluid through the proximal surface via the aperture.

[0023] In another embodiment, the chamber may extend within the frame body between a distal surface of the membrane and the distal surface of the frame.

[0024] In another embodiment, the plurality of layers may define a first region that includes a first structure material that exhibits a first acoustic property and a second region that includes a second structure material that exhibits a second acoustic property. The first and second regions may occupy different locations within the structure. The first and second structure materials may be different materials.

[0025] In another embodiment, the plurality of layers may define at least one cavity within the frame body.

[0026] In another embodiment, the plurality of layers may define at least a first cavity configured to receive a reinforcing material having a strength greater than a strength of the structure material.

[0027] In another embodiment, the plurality of layers may define at least a first cavity configured to receive a reinforcing material having a stiffness greater than a stiffness of the structure material.

[0028] In another embodiment, the plurality of layers may define at least a first cavity configured to receive a hardened material having a hardness greater than a hardness of the framework material.

[0029] In another embodiment, the plurality of layers may define at least one second cavity configured to reduce a weight of the structure compared to a comparable structure formed without the at least one second cavity.

[0030] In another embodiment, the plurality of layers may define one or more attachment features formed on or adjacent to the proximal surface thereof, and configured to secure the structure to the distal end of a probe fitting.

[0031] In another embodiment, the distal surface is curved and sized to abut a portion of an outer surface of a target.

[0032] In another embodiment, the method includes placing a wear resistant layer on at least a portion of the distal surface.

[0033] In another embodiment, the channel is configured to cause a fluid received from a probe fitting to flow in a laminar fashion from the proximal surface to the distal surface.

[0034] In another embodiment, the target is one of a tube, a bar, an ingot, or a track wheel.

[0035] In another embodiment, the target is formed from a composite material.

DESCRIPTION OF DRAWINGS

[0036] These and other features will be more readily understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0037] Figure 1 is a perspective view of an exemplary embodiment of an ultrasonic inspection apparatus that includes an ultrasonic probe and a probe fitting with a removable wear sole;

[0038] Figure 2 is a perspective view of the ultrasonic inspection apparatus of Figure 1 illustrating the ultrasonic probe and wear sole removed from the probe fitting;

[0039] Figure 3 is a cross-sectional view of the probe and test lead fitting of Figure 1;

[0040] Figure 4 is a perspective view of the wear sole of Figure 1;

[0041] Figure 5 is a cross-sectional view of the wear sole of Figure 4;

[0042] Figures 6A and 6B are cross-sectional views of the ultrasonic inspection apparatus of Figure 1;

[0043] Figure 7 is a cross-sectional view of another exemplary embodiment of a removable wear sole;

[0044] Figure 8 is a flowchart illustrating an exemplary embodiment of an ultrasonic inspection method;

[0045] Figure 9 is a flowchart illustrating an exemplary embodiment of a method for manufacturing a wear sole;

[0046] Figure 10A is a perspective view illustrating an exemplary embodiment of a wear sole formed according to the method of Figure 9 that includes cavities configured to receive wear resistant and/or reinforcing inlays, cavities for fluid guidance, and cavities configured for weight reduction;

[0047] Figure 10B is a side view illustrating another exemplary embodiment of a wear sole formed according to the method of Figure 9 that includes cavities configured for reduced weight; and

[0048] Figure 10C is a side view illustrating an additional exemplary embodiment of a wear sole formed according to the method of Figure 9 that includes a wear resistant layer positioned on a distal surface.

[0049] It should be noted that the drawings are not necessarily to scale. The drawings are intended to represent only typical aspects of the subject matter disclosed herein and therefore should not be considered as limiting the scope of the disclosure.

DETAILED DESCRIPTION

[0050] Methods, systems, and devices are provided for manufacturing wear components of ultrasonic inspection systems. Current ultrasonic inspection apparatus typically deliver ultrasonic waves through an ultrasonic couplant and into a target (e.g., a pipe), and measure ultrasonic waves reflected from the target. Each time the inspection apparatus is moved to a new location, the ultrasonic couplant must be restored, which results in a delay. Accordingly, a removable wear sole that retains a fixed amount of ultrasonic couplant within an ultrasonic inspection apparatus is provided, which requires only a small volume of ultrasonic couplant to be restored when the apparatus is moved. The wear sole can also be easily replaced when sufficiently worn. Embodiments of the wear sole can be manufactured through additive manufacturing, also called three-dimensional (3D) printing. In 3D printing, one or more materials are deposited layer by layer to form a wear sole structure. This allows for precise control over the composition and geometric features of the wear sole, which can in turn improve the properties of the wear sole. In one aspect, the wear sole can be formed from one or more materials that demonstrate specific properties, such as increased wear resistance, acoustic properties, fluid properties, reduced weight, increased stiffness, and increased strength, among others. In this manner, additively manufactured wear soles can be formed at reduced cost while exhibiting improved acoustic properties and/or longer service life. Other embodiments are within the scope of the disclosed subject matter.

[0051] Embodiments of the disclosure are discussed herein with respect to ultrasonic detection of defects within targets having the shape of tubes. However, one skilled in the art will appreciate that the disclosed embodiments may be employed in ultrasonic detection of defects in other structures and/or geometries without limitation. Examples may include bars, ingots, track wheels, and other structures formed from composite materials.

[0052] Figures 1 and 2 illustrate an exemplary embodiment of an ultrasonic inspection apparatus 10. As shown, the ultrasonic inspection apparatus 10 may include a probe fitting 20 having an ultrasonic probe 30 and a wear sole 40 mounted thereon. The probe fitting 20 may be configured to engage a pipe (not shown) via the wear sole 40 and retain a volume of ultrasonic couplant (or ultrasonic couplants) between the ultrasonic probe 30 and the pipe during inspection. Between inspections, the wear sole 40 may be easily removed from the probe fitting for replacement due to wear and accumulation of contaminants (e.g., dirt). As discussed in detail below, the probe fitting 20 and wear sole 40 may be configured such that when the ultrasonic inspection apparatus 10 is moved from one inspected pipe to another, a majority portion of the ultrasonic couplant (or ultrasonic couplants) is retained, while a minority portion is drained. Thus, the time required to replace the drained ultrasonic couplant (or ultrasonic couplants) is reduced, as compared to replacing the entire ultrasonic couplant (or ultrasonic couplants). Embodiments of the pipe may include any substantially tubular structure formed by any process and material (e.g., steels, copper and copper alloys, aluminum and aluminum alloys, etc.).

[0053] Figure 3 is a cross-sectional view illustrating the probe housing 20 and ultrasonic probe 30 of Figures 1 and 2. As shown, the probe housing 20 may be in the form of a generally rectangular housing or body having a first chamber 22 extending between a proximal end 20p and a distal end 20d. The first chamber 22 may be configured to receive the ultrasonic probe 30 and a first volume of ultrasonic couplant. As shown, a distal end 30d of the ultrasonic probe 30 may be inserted through an opening in the proximal end 20p of the probe housing 20 and secured therein. The distal end 30d of the ultrasonic probe 30 may be positioned within the first chamber 22 at a selected distance from the distal end 20d of the probe housing 20.

[0054] The first volume of ultrasonic couplant may be delivered to the first chamber 22 via a first couplant supply 24 (e.g., hoses, tubing, etc.) in fluid communication with the first chamber 22 and a first couplant source (not shown). The first couplant supply 24 may load the first chamber 22 with the first volume of the first ultrasonic couplant. In Figure 3, the first couplant supply 24 is illustrated extending through the proximal end 20p of the probe fitting 20. However, in alternative embodiments, the first couplant supply may extend through the probe fitting in other directions for fluid communication with the first chamber.

[0055] The probe fitting 20 may also define a first fluid channel 26 configured to receive a second volume of ultrasonic couplant. The first and second volumes of ultrasonic couplants may be the same ultrasonic couplant or different ultrasonic couplants. As shown, the first fluid channel 26 may extend from a side surface of the probe fitting 20 to the distal end 20d of the probe fitting 20. The first fluid channel 26 may also extend along at least a portion of a length of the probe fitting 20. In certain embodiments, the first fluid channel 26 does not fluidly communicate with the first chamber 22. The first fluid channel 26 may be placed in fluid communication with a second source of ultrasonic couplant (not shown) and may direct a flow of ultrasonic couplant through the probe fitting 20 to the distal end 20d.

[0056] In certain embodiments, the probe housing 20 may be formed from multiple components. For example, the probe housing 20 may include a proximal portion 28p sealingly engaged with a distal portion 28d at a joint 32. The joint 32 may include an interface between opposing surfaces of the proximal and distal body portions, and one or more seals 34 positioned around the circumference of the first chamber 22 at the interface. The seals 34 may inhibit leakage of the first volume of ultrasonic couplant when retained in the first chamber 22.

[0057] Figures 4 and 5 illustrate the wear sole 40 in more detail. In an exemplary embodiment, the wear sole 40 may include a structure 42 (e.g., a generally rectangular structure) having a proximal surface 42p, a distal surface 42d, and an opening 46 extending therethrough. The proximal surface 42p of the structure 42 may be configured to mate with the distal end 20d of the probe socket 20. The structure 42 may also include a tab 44 extending laterally over and/or adjacent to the proximal surface 42p. The tab 44 may be sized for reception within a slot 36 formed at the distal end 20d of the probe fitting 20. As an example, the tab 44 may be secured within the slot 36 via an interference fit, which allows the wear sole 40 to be quickly engaged or disengaged from the probe fitting 20. In alternative embodiments, other mechanisms (e.g., mechanical latches, adhesives, etc.) may be employed in place of, or in combination with, the slot 36 and the tab 44 to couple the wear sole 40 to the probe fitting 20.

[0058] The distal surface 42d of the structure 42 may be configured to engage a tube. In certain embodiments, the distal surface 42d may have a radius of curvature that is equal to or approximately equal to that of a tube to be inspected. In other embodiments, the distal surface 42d may adopt any other shape (e.g., rectilinear, curved, arbitrary, etc.) suitable for mating with a surface of a tube or other object to be inspected. For example, the wear sole may be a stiffening system with respect to a fixed geometry of a test piece or a flexible system as described in International Patent Publication No. WO 2013/127871, which is incorporated by reference herein in its entirety. Although not shown, additional embodiments of the structure 42 may include a plurality of recesses formed in the distal surface 42d that retain a wear resistant material therein (e.g., hardened steels, ceramics, etc.) to enhance the durability and service life of the wear sole 40.

[0059] The structure 42 may also include a membrane 48 positioned within the aperture 46. In certain embodiments, the membrane 48 may be proximally offset from the distal surface 42d of the structure 42 (e.g., mounted flush with the proximal surface 42p) and may define a second chamber 50 distal to the membrane 48. As shown, the second chamber 50 may be bound by sidewalls of the aperture 46 and proximally bound by the membrane 48. That is, the second chamber 50 may be open to the distal surface 42d of the structure 42. The membrane 48 may also seal the second chamber 50 from the first chamber 22 when the wear sole 40 is coupled to the probe fitting 20.

[0060] This configuration of the inspection apparatus 10 can significantly reduce the time required for ultrasonic inspection. As discussed in greater detail below, when the inspection apparatus 10 is moved from one inspection location to another, the first volume of ultrasonic couplant received within the first chamber 22 can be retained within the first chamber 22 rather than being drained from the first chamber 22. Thus, only ultrasonic couplant received within the second chamber 22 (e.g., a second volume of ultrasonic couplant) is drained and replenished between ultrasonic inspection runs performed at different test locations. As a result, a replenishment time between ultrasonic inspection runs can be reduced.

[0061] In certain embodiments, membrane 48 may be formed from a material having selected acoustic and/or mechanical properties. As an example, membrane 48 may be formed from a material whose acoustic impedance is matched with the ultrasonic couplant (or ultrasonic couplants) in contact with membrane 48 to minimize reflections and absorptions at interfaces between the membrane and the ultrasonic couplant (or ultrasonic couplants). In certain example embodiments, a membrane material may be a material that is invisible or nearly invisible when used with a selected couplant, such that the material does not reflect ultrasound from the surface and does not absorb ultrasound when waves pass therethrough, or at least minimizes reflection and absorption. In additional embodiments, membrane 48 may be formed from a mechanically rigid material. It may be desirable for the membrane 48 to be substantially rigid, being subjected to less than a selected amount of deflection in response to forces exerted on the membrane 48 due to the ultrasonic couplant (or ultrasonic couplants) in use (e.g., fluid flow pressure, force of gravity, etc.). Accordingly, the membrane 48 may have an elastic modulus that limits the deflection of the membrane 48 to less than the selected amount.

[0062] By way of example without limitation, suitable membrane materials include, but are not limited to, polymers, polymer blends and rubber materials such as polyethylene, polypropylene, polyvinyl chloride, polystyrene, polytetrafluoroethylene, polymethyl methacrylate, polyacrylnitrile, polyacrylamide, aramids, polyetherketones, polyethylene glycol, polyurethane, silicones or poly(organo)siloxane, thermoplastic elastomers, melamine resin, polyacrylate rubber, ethylene acrylate rubber, polyester urethane, bromoisobutylene isoprene, polybutadiene, chloroisobutylene isoprene, polychloroprene, chlorosulfonated polyethylene, epichlorohydrin, ethylene propylene, ethylene propylene diene monomer, polyether urethane, perfluorocarbon rubber, fluorinated hydrocarbon, fluorosilicone, polyethylene rubber, polyethylene rubber, polyethylene propylene, polyethylene propylene diene monomer, polyether urethane, perfluorocarbon rubber, fluorinated hydrocarbon, fluorosilicone, polyethylene rubber ... fluorocarbon, hydrogenated nitrile butadiene, polyisoprene, isobutylene isoprenebutyl, acrylonitrile butadiene, butyl rubber, styrene butadiene, ethylene butylene styrene copolymer, polysiloxane, vinylmethyl silicone, acrylonitrile butadienecarboxy monomer, styrene butadienecarboxy monomer, thermoplastic polyether ester, styrene butadiene block copolymer, and styrene butadienecarboxy block copolymer. An exemplary membrane material is Aqualene™, manufactured by Innovation Polymers of Kitchener, Ontario, Canada.

[0063] The structure 42 may also be configured to receive an ultrasonic couplant and deliver the ultrasonic couplant to the second chamber 50. The second chamber 50 may be in fluid communication with a second fluid channel 52 that extends through the structure 42 (e.g., from the proximal surface 42p of the structure 42 to the second chamber 50). The second fluid channel 52 may extend along at least a portion of the length of the aperture 46. When the second fluid channel 52 is placed in fluid communication with a source of the second ultrasonic couplant (not shown), the second volume of ultrasonic couplant may flow therethrough to load the second chamber 50. As shown, the second fluid channel 52 includes one or more dividers 52d that separate the second fluid channel into a plurality of fluid passageways 52p

[0064] Figure 6A illustrates a cross-sectional view of the ultrasonic inspection apparatus 10 with the wear sole 40 coupled to the probe fitting 20. As shown, the tab 44 of the wear sole 40 may extend into the slot 36 of the probe fitting 20 to removably couple the wear sole 40 to the probe fitting 20. Coupled in this manner, various features of the probe fitting 20 and the wear sole 40 may be aligned with respect to each other for ease of use. When the ultrasonic probe 30 is mounted on the probe fitting 20 within the first chamber 22, the distal end 30d of the ultrasonic probe 30 may be positioned at a fixed distance and orientation with respect to the wear sole 40. This mounting may provide a line of sight from the distal end 30d of the ultrasonic probe 30 to the distal surface 42d of the structure 42, through the membrane 48, without obstruction of the probe fitting 20 or the structure 42. In another aspect, ends of the first and second fluid channels 26, 52 may be aligned across opposing surfaces of the probe fitting 20 and the wear sole 40 to form a continuous fluid delivery channel 60. The fluid delivery channel 60 may allow an ultrasonic couplant to flow within the probe fitting 20 and the structure 42 of the wear sole. 40 to load the second chamber 50.

[0065] Figure 6B illustrates a cross-sectional view of ultrasonic inspection apparatus 10 positioned in a tube 62 for performing an ultrasonic inspection. As shown, distal surface 42d of wear sole structure 42 40 may be placed in contact with or adjacent to an outer surface of tube 62, remote from an outer surface of tube 62 by distal end 30d of ultrasonic probe 30. First chamber 22 may be loaded with first volume of ultrasonic couplant via first couplant supply 24 (arrow A), and second chamber 50 may be loaded with second volume of ultrasonic couplant via fluid delivery channel 60 (arrow B). When the distal end 20d of the probe fitting 20 is sealingly engaged by the membrane 48, the first volume of ultrasonic couplant carrying the first chamber 22 (V1) may be substantially constant during inspection and movement of the ultrasonic inspection apparatus 10. In contrast to the first chamber 22, the second chamber 50 may be open to the distal surface 42d of the frame 42 and the tube 62. When the distal surface 42d of the frame 42 is positioned on the tube 62, the second chamber 50 becomes distally connected and the second volume of ultrasonic couplant received within the second chamber 50 (V2) may flow in contact with the outer surface of the tube 62.

[0066] Under the influence of gravity and/or flow pressure, the second volume of ultrasonic couplant may also flow out of the second chamber 50 via a third fluid channel 64 (arrow C). The third fluid channel 64 may be formed on the distal surface 42d of the structure 42 and be positioned laterally opposite the second fluid channel 52. In certain embodiments (not shown), the third fluid channel may be formed with two or more slits. As an example, each of the slits may be approximately the same width.

[0067] Thus, an ultrasonic couplant received within the second fluid channel 52 may flow laterally through one side of the structure 42 that includes the second fluid channel 52, through the second chamber 50, and through the opposite side of the structure 42 that includes the third fluid channel 64. To maintain the volume of the second chamber 50 (V2) loaded with the second volume of ultrasonic couplant, a continuous stream of ultrasonic couplant may be delivered to the second chamber 50 via the fluid delivery channel 60. In this manner, an optimized flow path may be formed by the first channel 26, the second fluid channel 52, and the third fluid channel 64 in combination with the second chamber 50.

[0068] Alternatively or additionally, the cross-sectional area of the second fluid channel 52 may be larger than the cross-sectional area of the third fluid channel 64. This configuration may facilitate retention of the second volume of ultrasonic couplant within the second chamber 50, as fluid flowing out of the second chamber 50 is restricted relative to fluid flowing into the second chamber.

[0069] Since the first and second chambers 22, 50 are loaded with the first and second volumes of ultrasonic couplants, respectively, the ultrasonic probe 30 can transmit ultrasonic waves toward the pipe for inspection. Ultrasonic waves 66t transmitted by ultrasonic probe 30 may propagate through the first ultrasonic couplant volume within first chamber 22, through membrane 48, and through the second ultrasonic couplant volume within second chamber 50 to tube 62. At tube 62, ultrasonic waves 66r may be reflected from the surface and/or internal boundaries of tube 62 back toward ultrasonic probe 30, which propagates through the second ultrasonic couplant volume within second chamber 50, membrane 48, and the first ultrasonic couplant volume within first chamber 22. At ultrasonic probe 30, characteristics of the reflected ultrasonic waves 66r may be measured (e.g., amplitude, propagation time, etc.) and transmitted to a computing device for storage and/or analysis for detection of defects within the tube. 62.

[0070] After the ultrasonic probe 30 completes acquiring measurements for a pipe, the ultrasonic inspection apparatus 10 may be removed from contact with the pipe 62 and/or repositioned relative to the pipe 62. The second volume ultrasonic couplant (V2) may drain from the second chamber 50 through the open distal surface 42d of the structure 42 when the pipe 62 is removed, although the first of the ultrasonic couplant (V1) within the first chamber 22 may be retained. The first and second chambers 22, 50 may be configured such that the volume V1 is larger than the volume V2, so that the first volume of ultrasonic couplant occupies the majority of the path through which the ultrasonic waves 66t, 66r travel between the distal end 30d of the ultrasonic probe 30 and the tube 62. As an example, the ratio of V1 to V2 may be in the range of about 2 to 1, 3 to 1, 4 to 1, 5 to 1, 10 to 1, 20 to 1, 30 to 1, 40 to 1, etc. In one non-limiting example, the ratio of V1 to V2 may be in the range of about 34 to 1. Thus, when the ultrasonic inspection apparatus 10 is disengaged from one pipe and engaged with another pipe, the second volume of ultrasonic couplant within the second chamber 50 (V2) is drained and the first volume of ultrasonic couplant within the first chamber 22 (V1) is retained, which reduces the loading time required to prepare the ultrasonic inspection apparatus 10 for inspection of the next pipe as compared to a circumstance in which the first and second volumes of ultrasonic couplants (V1 + V2) from both the first and second chambers 22, 50 are drained.

[0071] Figure 7 is a cross-sectional view illustrating another exemplary embodiment of removable wear sole 40 in the form of removable wear sole 40'. Wear sole 40' may be similar to wear sole 40 except that third fluid channel 64 is replaced by third fluid channel 64'. Like third fluid channel 64 of wear sole 40, third fluid channel 64' of wear sole 40' may be in fluid communication with second chamber 50 and distal surface 42d of frame 42. Thus, the functionality and advantages discussed herein with respect to third fluid channel 64 are also applicable to third fluid channel 64'. However, in contrast to the third fluid channel 64, which may be formed on the distal surface 42d of the structure 42, the third fluid channel 64' may be formed within the batch of the structure 42, wherein the terminal ends of the third fluid channel 64' may be in fluid communication with the second chamber 50 and the distal surface 42d of the structure 42.

[0072] Formation of the third fluid channel 64' through the batch of structure 42 may be advantageous in operating environments where the wear sole is expected to experience significant wear. The wear experienced by the wear sole may substantially remove some portion of the distal facing surface 42d of structure 42. If the degree of such wear is extreme, it may potentially cause removal of a portion of the third fluid channel 64 and compromise the ability of the third fluid channel 64 to guide fluid leaving the second chamber 50. In contrast, formation of the third fluid channel 64' through the batch of structure 42 may substantially avoid this issue.

[0073] In alternative embodiments of the inspection apparatus, the probe attachment may be omitted. As an example, the ultrasonic probe may be attached directly to the membrane 48 by an adhesive or other attachment mechanism (e.g., straps, hook and loop fasteners, etc.)

[0074] Figure 8 is a flowchart illustrating an exemplary embodiment of a method 800 for ultrasonic inspection. Embodiments of method 800 are described below with reference to inspection apparatus 10. In certain aspects, embodiments of method 800 may include more or fewer operations than illustrated in Figure 8 and may be performed in a different order than illustrated in Figure 8.

[0075] In operation 802, a wear sole (e.g., 40, 40') may be removably coupled to a distal end (e.g., 20d) of a probe fitting (e.g., 20).

[0076] In operation 804, the probe fitting 20 may be positioned in contact with an outer surface of a target (e.g., pipe 62) via the wear sole 40, 40'. In alternative embodiments, the distal surface 42d of the wear sole 40 may be positioned adjacent the outer surface of the target. As an example, the distal surface 42 of the wear sole 40 and the outer surface of the target may remain separated from each other due to the pressure of ultrasonic couplant interposed therebetween.

[0077] In operation 806, a first chamber (e.g., 22) of the probe fitting 20 may be loaded with a first volume of an ultrasonic couplant.

[0078] In operation 810, a second chamber (e.g., 50) may be loaded with a second volume of ultrasonic couplant. The second chamber 50 may extend between the wear sole 40, 40' and the tube 62. As an example, the wear sole 40, 40' may include a membrane (e.g., 48) that separates the first chamber 22 from the second chamber 50, and the second chamber 50 may extend from the membrane 48 and the tube 62. The second volume of ultrasonic couplant may also be in fluid contact with the tube 62. In certain embodiments, the second volume of fluid couplant may be delivered to the second chamber 50 by a fluid channel (e.g., 60) that extends through the probe fitting 20 and the wear sole 40, 40'.

[0079] The first and second ultrasonic couplant volumes may have a variety of configurations. In one aspect, the first ultrasonic couplant volume in the first chamber 22 may be larger than the second ultrasonic couplant volume in the second chamber 50. In another aspect, the first ultrasonic couplant volume may be approximately constant, while the second ultrasonic couplant volume may be continuously delivered to the second chamber 50 to charge the second chamber 50.

[0080] In operation 812, ultrasonic waves generated by an ultrasonic transducer (e.g., 30) may be propagated through the first ultrasonic couplant volume, through the membrane 48, and through the second ultrasonic couplant volume to the tube. The membrane 48 may be configured to propagate ultrasonic waves emitted by the ultrasonic probe 30. That is, the membrane 48 may be substantially transparent to ultrasonic waves.

[0081] Optionally, the method may also include removing a first wear sole from the probe fitting and replacing the first wear sole with a second wear sole. The first and second wear soles may be substantially the same except for the wear experienced by the first wear sole during use.

[0082] In additional embodiments, a method 900 is provided for forming a wear sole (e.g., wear sole 40) in a layer-by-layer manner (e.g., additive manufacturing). As shown in Figure 9 , the method includes operations 902 and 904. The operations of method 900 are further discussed with respect to Figures 1-7 and 10A-10C . In certain embodiments, method 900 can provide one or more of a reduction in manufacturing cost, increased wear resistance, and reduced weight.

[0083] In operation 902, a plurality of layers are formed from at least one frame material. Adjacent layers of the plurality of layers may be bonded to one another to define the frame of the wear sole 40. The wear sole 40 formed in this manner may include proximal surface 42p, distal surface 42d, a frame body 42b extending between proximal surface 42p and distal surface 42d, aperture 46, and one or both of second fluid channel 52 and third fluid channel 64.

[0084] As discussed above, the wear sole 40 may be coupled to the probe fitting 20 and at least a portion of the distal surface 42d of the wear sole 40 may be placed in contact with the target (e.g., tube 62). The second fluid channel 52 formed within the wear sole 40 may be configured such that the second volume of fluid couplant received by the second fluid channel 52 flows from the proximal surface 42p to the distal surface 42d. In certain embodiments, the second fluid channel 52 may be configured to cause the second received volume of fluid couplant to flow in a laminar fashion (e.g., non-turbulent flow) between the distal surface 42d and an outer surface of the target (e.g., tube 62).

[0085] As an example, laminar flow may be created by the design of the wear sole 40. In one aspect, laminar flow between the distal surface 42d and an outer surface of the target may be achieved by avoiding the formation of edges and ridges within the second fluid channel 52. In another aspect, laminar flow between the distal surface 42d and an outer surface of the target may be achieved by maintaining fluid flow in adjacent fluid pathways 52p at similar velocities (e.g., from about 1 m/s to about 3 m/s) before merging the fluid flow in the second chamber. In a further aspect, laminar flow between the distal surface 42d and an outer surface of the target can be achieved by eliminating boundaries within the second fluid channel that can create reverse flows (e.g., geometric discontinuities such as edges and perturbers and changes in cross-sectional area). In a further aspect, laminar flow between the distal surface 42d and an outer surface of the target can be achieved by maintaining a fluid flow path at small angle deviations (e.g., from about 0° to about 10°) relative to an improved direction of the main fluid flow. Laminar flow can also be created through iterative improvement with simulation, testing, and redesign.

[0086] Exemplary embodiments of the wear sole 40 formed in this manner are illustrated in Figures 10A-10C as wear soles 1000, 1020, 1040. As shown, in Figure 10A, layers 1002 of the predetermined shape are formed into each other in at least one direction (e.g., a thickness direction) to define structure 42. For purposes of clarity, layers 1002 are not shown in Figures 10B-10C. Each of the wear soles 1000, 1020, 1040 includes structure 42, proximal surface 42p, distal surface 42d, a structure body 42b, aperture 46, second fluid channel 52, and third fluid channel 64.

[0087] A thickness T of the respective layers 1002 may be approximately the same or different from each other. In one embodiment, the thickness T of each of the layers 1002 may be independently selected from the range of about 0.001 mm to about 0.5 mm.

[0088] The proximal surface 42p may be configured to secure the structure 42 to the distal end 20d of the probe socket 20. That is, the plurality of layers may define one or more attachment features that are configured to secure the structure 42 to the distal end 20d of the probe socket 20. As an example, the wear soles 1000, 1020, 1040 may include tab 44 and tab 44 may be received within slot 36 of the probe socket 20 by an interference fit to secure the wear sole 1000 to the probe socket 20. In alternative embodiments, the attachment features may be formed on or adjacent to the proximal surface 42p. As an example, the attachment features may include recesses 1004 extending proximally from proximal surface 42p (e.g., for frame body 42b) and/or protrusions 1006 extending distally from proximal surface 42p. Probe socket 20 may include corresponding features configured to engage such recesses and/or protrusions.

[0089] In one embodiment, the plurality of layers may be formed through one or more additive manufacturing techniques. Examples of additive manufacturing may include VAT photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, and directed energy deposition, alone or in any combination. Examples of the structure material may include, thermoplastics (e.g., polyamide [PA], acrylonitrile butadiene styrene [ABS], polylactic acid [PLA]), photopolymers (e.g., SU-8), and steels (e.g., stainless, copper, aluminum). The printed matrix may include any filler material that may increase strength, such as carbon fiber, fiberglass, Kevlar® (DuPont, Wilmington, DE, USA), etc.

[0090] In VAT photopolymerization, a substrate is lowered into a vat of liquid photopolymer resin at layer thickness T. The resin is the framework material and, when exposed to ultraviolet (UV) light, is cured to form a first layer in a predetermined shape. Subsequently, the substrate is lowered back into the resin at layer thickness T and the ultraviolet (UV) light cures the resin to form a second layer in a predetermined shape that is positioned over and bonded to the first layer. This process of lowering the substrate into the framework material resin and curing the resin is repeated to form as many layers as necessary to complete the structure 42.

[0091] In material jetting, a print head is positioned above a substrate. Droplets of structure material are deposited from the print head in a predetermined shape on the substrate. After deposition, the droplets of structure material solidify to form the first layer. The droplets of structure material are subsequently deposited from the print head in a predetermined shape on the first layer. After deposition, the droplets of structure material solidify to form the second layer in a predetermined shape that is positioned on and bonded to the first layer. This process of depositing and solidifying the structure material is repeated to form as many layers as necessary to complete structure 42.

[0092] In binder jetting, a powder of the structure material is spread onto a substrate (e.g., using a roller). A print head then deposits a binder adhesive onto the powder in a predetermined shape to form the first layer. The substrate is then lowered to layer thickness T and the process is repeated to form the second layer in a predetermined shape on the first layer. This process of depositing the powder of structure material and binder adhesive is repeated to form as many layers as necessary to complete the structure 42. Examples of the binder may include, but are not limited to, polymeric adhesives.

[0093] In material extrusion, a first layer of the structure material is heated and deposited onto a substrate by extrusion from an extrusion head (e.g., a nozzle) in a predetermined shape. A second layer of the structure material is similarly heated and deposited in a predetermined shape on the first layer. Adjacent layers may be fused upon deposition, to the extent that the extruded structure material is in a fluidifiable state having a predetermined viscosity (e.g., at least partially molten). This process of heating and extruding the structure material is repeated to form as many layers as necessary to complete the structure 42. This process is repeated until the structure 42 is completely formed.

[0094] In powder bed fusion, a powder of the framework material is deposited on a substrate. A laser melts the deposited framework material powder into a predetermined shape to form the first layer. A new layer of framework material powder is deposited on the first layer, and a laser melts the deposited framework material powder into a predetermined shape to form the second layer. Adjacent layers may be bonded together by melting. This process of depositing and fusing the powdered framework material is repeated to form as many layers as necessary to complete the structure 42. Specific embodiments of powder bed fusion may include direct metal laser sintering (DMLS), electron beam melting (EBM), selective thermal sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS).

[0095] In sheet lamination, sheets of the structure material are stacked and bonded together. The sheets may be cut to their predetermined shapes and then bonded together, or bonded together and then cut to a predetermined shape. Specific embodiments of sheet lamination may include ultrasonic additive manufacturing (UAM) and laminated object manufacturing (LOM).

[0096] In directed energy deposition, a multi-axis arm (e.g., 4-axis, 5-axis, etc.) equipped with a nozzle moves around an object that is fixed in place. Structure material is deposited from the nozzle (e.g., in a powder or wire form) onto existing surfaces of the object. After deposition, the structure material may be melted using a laser, electron beam, or plasma arc and subsequently solidified into a predetermined shape to form the first layer. A new layer of structure material is deposited on the first layer and is melted and solidified into a predetermined shape to form the second layer. Additional layers are built up in the same manner, where cooling of each molten layer results in bonding to the layer underlying it. This process is repeated until the structure 42 is completely formed. Additive manufacturing may enable the formation of wear soles that exhibit new features and designs. Examples of features that can be formed are illustrated in Figures 10A through 10C.

[0097] In one embodiment, the plurality of layers may define a first region 1008a that includes a first structure material that exhibits a first acoustic property and a second region 1008b that includes a second structure material that exhibits a second acoustic property. The first and second regions 1008a, 1008b may occupy different locations within the structure and the first and second structure materials may be different materials.

[0098] Examples of the first and second frame materials may be independently selected from elastomers, polymers having a predetermined strength (e.g., tensile, compressive, and/or flexural strength from the range of about 10 MPa to about 80 MPa), steels, metal alloys, unhardened steels, unhardened metal alloys, uncured (e.g., uncrosslinked) polymers.

[0099] The relative fractions of the first and second regions 1008a, 1008b, and their relative placements within the frame body 42b, are configured to conform to one or more acoustic properties of the frame 42. Configurations of the first and second regions 1008a, 1008b may include one or more entire layers of the plurality of layers and portions thereof. The first and second regions 1008a, 1008b may be arranged in a continuous or discontinuous manner according to a predetermined pattern. Examples of arrangements of the first and second regions 1008a, 1008b may include patterns to create acoustic properties, such as parallel structures or checked patterns. In certain embodiments, the first and second regions 1008a, 1008b may be configured to achieve acoustic attenuation within a range of normalized viscosities from about 2 MPa*s/m to about 10 MPa*s/m (e.g., by adjusting their respective volume fractions). In additional embodiments, the acoustic impedance of the wear sole may range from about 2.2 MRayl to about 3 MRayl (mega Rayleigh units of acoustic impedance).

[00100] In other embodiments, the attenuation within a material may optionally be a function of a build direction. That is, a direction in which the layer containing the material is oriented with respect to the geometry of the wear sole 40. As an example, the specific attenuation of a first structure material within the first region 1008a may range from about 10 dB/cm to about 15 dB/cm and the specific attenuation of a second structure material within the second region 1008b may range from about 45 dB to about 55 dB, depending on whether the build direction is to the side, bottom, or back of the wear sole 40. Advantageously, a 3D printing device forming the wear sole 40 may be configured to vary the build directions of different portions of the wear sole 40 to provide desired acoustic properties. It may be understood, however, that in alternative embodiments, acoustic properties of a given layer and/or the wear sole as a whole may be configured to vary in any direction of interest, regardless of whether or not that direction is the construction direction.

[00101] As an example, the first region may include a layer formed from a fully bonded polymeric material and the second region may include unbonded polymer powder. The first and second regions may be arranged in an alternating manner, wherein the first region of fully bonded polymer restrains the unbonded polymer powder of the second region. Such layers may be arranged in parallel layers, each having a thickness of about 1 mm. In this manner, structure 42 may exhibit the acoustic property of nearly complete attenuation within a normalized viscosity range of about 5 MPa*s/m to about 10 MPa*s/m.

[00102] In additional embodiments, as shown in Figures 10A and 10B, the plurality of layers may define at least one cavity within the frame body 42b.

[00103] In one aspect, at least one first cavity 1010 may be configured to receive a reinforcing material, different from the structure material (e.g., first and/or second structure materials). In one embodiment, the reinforcing material may exhibit a higher strength (e.g., compressive strength, tensile strength, and/or flexural strength) than the structure material. In this manner, the strength of the structure 42 may be increased. As an example, the reinforcing material may exhibit a strength within the range of 100 MPa to about 4,000 MPa. Examples of the reinforcing material may include carbon fiber, fiberglass, steel alloys, ceramic inlays, Kevlar® inlays, etc.

[00104] In another embodiment, the reinforcing material may exhibit a higher stiffness (e.g., elastic modulus) than the frame material. As an example, the reinforcing material may exhibit an elastic modulus within the range of 100 GPa to about 4,000 MPa. Examples of reinforcing materials may include carbon fiber, fiberglass, steel alloys, ceramic inlays, Kevlar® inlays, etc. In this manner, a stiffness of the frame 42 may be increased.

[00105] In another aspect, the at least one first cavity 1010 may be sized to receive a hardened material that exhibits specific wear properties. The hardened material may exhibit a greater wear resistance (e.g., hardness) than the structure material. In this manner, the wear resistance and service life of the wear sole may be increased. As an example, the hardened material may exhibit a hardness within the range of about 100 MPa to about 450 MPa. The hardened material may include one or more of hardened metals, ceramics, reinforced plastics, and combinations thereof. Additional examples of hardened material may include ceramics (e.g., aluminum oxide), nitrided hardened metal shells, etc.

[00106] Embodiments of method 900 may incorporate the reinforcing material into the frame body 42b in a variety of ways. In one aspect, the at least one first cavity 1010 may be formed as void space that is subsequently loaded with the reinforcing material. In another aspect, the reinforcing material may be formed locally within the at least one first cavity 1010. That is, simultaneously with the layers 1002.

[00107] Embodiments of the shape and placement of the at least one first cavity 1010 within the frame body 42b may be varied. In one aspect, the shape of the at least one first cavity 1010 may be round, elliptical, or polygonal. As shown in Figure 10A, the at least one first cavity 1010 may have a generally tubular shape (e.g., have a generally circular cross-section) that extends along at least a portion of the length of the frame 42. The at least one first cavity 1010 may be positioned proximate to the distal surface 42d (e.g., at a distance of about 0.1 mm to about 3 mm from the distal surface 42) within the frame body 42b.

[00108] The at least one first cavity 1010 may occupy a predetermined fraction of the wear sole 1000, 1020. As an example, the at least one first cavity 1010 may occupy a fraction of the wear sole 1000, 1020 selected from the range of about 1 volume % to about 10 volume % based on the total volume of the frame body 42b.

[00109] In another aspect, as illustrated in Figures 10A and 10B, the plurality of layers may define at least one second cavity 1022 within the frame body 42b. The at least one second cavity 1022 may be an unloaded void space configured to reduce a weight of the frame 42 compared to a comparable frame formed without the at least one second cavity 1022. In this manner, a weight of the wear sole 1000, 1020 may be reduced.

[00110] Embodiments of the shape and placement of the at least one second cavity 1022 within the frame body 42b may be varied. In one aspect, the shape of the at least one second cavity 1022 may be round, elliptical, or polygonal. As shown in Figure 10B, the at least one second cavity 1022 may have a generally tubular shape that extends along at least a portion of the length of the frame 42 (e.g., toward the page) and has a generally triangular cross-section. The at least one second cavity 1022 may be positioned in any area within the frame body 42b.

[00111] The at least one second cavity 1022 may occupy a predetermined fraction of the wear sole 1000, 1020. As an example, the at least one second cavity 1022 may occupy a fraction of the wear sole 1000, 1020 that is selected from the range of about 1 volume % to about 50 volume % based on the total volume of the frame body 42b.

[00112] In another embodiment, illustrated in Figure 10C, a hardened material 1042, other than the structure material, may be positioned on at least a portion of the distal surface 42d. As discussed above, the distal surface 42d may be configured to contact the target. As shown in Figure 10C, the distal surface 42d may be curved and sized to abut at least a portion of an outer surface of a curved target, such as a tube. In other embodiments, the shape of the distal surface may be configured to match the outer surfaces of targets that have different shapes (e.g., flat, non-circular, etc.).

[00113] The hardened material 1042 may exhibit specific wear properties, such as greater wear resistance (e.g., hardness) than the frame material. As an example, the hardened material 1042 may exhibit a hardness within the range of about 160 GPa to about 450 GPa. The hardened material 1042 may include one or more of hardened metals, ceramics, reinforced plastics, and combinations thereof. Additional examples of the hardened material 1042 may include carbon fiber, fiberglass, steel alloys, ceramics (e.g., aluminum oxide), nitriding-hardened metal casing, etc. Non-hardened materials, such as brass alloys, may also be employed to improve wear properties. In this manner, the wear resistance and service life of the wear sole may be increased.

[00114] Embodiments of method 900 may position hardened material 1042 on distal surface 42d in a variety of ways. In one aspect, after structure 42 is formed from the plurality of layers, hardened material 1042 may be positioned on at least a portion of distal surface 42d. In another aspect, hardened material 1042 may be formed locally. That is, simultaneously with layers 1002 of the plurality of layers.

[00115] As shown in Figure 10A, aperture 46 extends through proximal surface 42p, frame body 42b, and distal surface 42d. In operation 904 of method 900, membrane 48 may be placed within aperture 46. Membrane 48 may be coupled to frame 42 by a substantially fluid-tight seal that inhibits the passage of a fluid from proximal surface 42p through aperture 46.

[00116] Thus configured, the second fluid channel 52 may extend from the proximal surface 42p to the chamber 50 that extends laterally between the side walls of the aperture 46, which extend proximally into a distal surface of the membrane and distally through the intersection of the aperture 46 and the distal surface 42d of the structure 42.

[00117] The membrane 48 may be placed within the opening 46 in a variety of ways. In one aspect, after the structure 42 is formed from the plurality of layers, the membrane 48 may be positioned within the opening 46. An adhesive or other sealing mechanism may be employed to form the substantially fluid-tight seal. In another aspect, the membrane 48 may be formed locally. That is, simultaneously with the layers 1002.

[00118] It can be understood that embodiments of the disclosure can be employed to manufacture wear soles having different configurations than wear sole 40. In one aspect, the first and second fluid channels 26, 52 can be omitted and couplant can be directed to the second chamber 50 by one or more alternative mechanisms. As an example, a pressurized flow of couplant can be directed to the second chamber 50 from outside the wear sole.

[00119] Exemplary art effects of the methods, systems, and devices described herein include, by way of example and without limitation, the ability to direct ultrasonic couplants from a probe fitting through a wear sole of an ultrasonic inspection apparatus, a reduction in inspection delays arising from the replacement of drained ultrasonic couplants, and rapid wear sole replacement. Through the use of additive manufacturing techniques, wear soles can be formed at lower cost and with improved properties (e.g., wear resistance, weight reduction, etc.)

[00120] Certain exemplary embodiments have been described to provide a general understanding of the principles of structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of such embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are exemplary embodiments without limitation, and that the scope of the present invention is defined solely by the claims. Features illustrated or described in conjunction with an exemplary embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. Furthermore, in the present disclosure, similarly named components of embodiments generally have similar features, and thus, within a particular embodiment, each feature of each similarly named component is not necessarily elaborated upon completely.

[00121] Approximate language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that may be permissibly varied without resulting in a change in the basic function to which it relates. Accordingly, a value modified by a term or terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some examples, approximate language may correspond to the precision of an instrument for measuring the value. In the present context and throughout the specification and claims, range limitations may be combined and/or alternated; such ranges are identified and include all subranges contained therein, unless the context or language indicates otherwise.

[00122] One skilled in the art will appreciate additional features and advantages of the invention based on the embodiments described above. Accordingly, the present application is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated by reference in their entirety.

Claims (15)

1. A method of forming a structure (42) of a wear sole (40) for an ultrasonic inspection apparatus (40), the method comprising: forming a plurality of layers (1002) from at least two structure materials, wherein adjacent layers of the plurality of layers (1002) are bonded to one another to define a structure (42) of a wear sole (40), the method including forming: a proximal surface (42p) configured to secure the structure (42) to a distal end of a probe fitting (20), a distal surface (42d) configured to contact a portion of a target surface; a structure body (42b) extending between the proximal and distal surfaces (42p, 42d); an aperture (46) extending through the proximal surface (42p), the body (42b), and the distal surface (42d); and 1. a channel (52) extending from the proximal surface (42p) to a chamber (50) in fluid communication with the distal surface (42d); wherein the plurality of layers define a first region (1008a) including a first framework material exhibiting a first acoustic property and a second region (1008b) including a second framework material exhibiting a second acoustic property, wherein the first and second regions (1008a, 1008b) occupy different locations within the framework (42), the relative fractions of the first and second regions (1008a, 1008b) and their relative placement within the framework body (42b) being configured to adapt one or more acoustic properties of the framework (42). 2. The method of claim 1, further comprising placing a membrane (48) within the opening (46) adjacent to the proximal surface (42p), wherein the membrane (48) is coupled to the frame body (42b) by a fluid-tight seal so as to inhibit the passage of a fluid through the proximal surface via the opening (46). 3. The method of claim 2, wherein the chamber (50) extends within the frame body (42b) between a distal surface of the membrane (48) and the distal surface of the frame (42d). 4. Method according to any one of the preceding claims, characterized in that the first and second structure materials are different materials. 5. Method according to claim 1, characterized in that the plurality of layers (1002) define at least one cavity within the structure body (42b). 6. The method of claim 5, wherein the plurality of layers (1002) define at least one first cavity (1010); the method further comprising receiving a reinforcing material having a strength greater than the strength of the at least one structure material in the at least one first cavity. 7. The method of claim 5, wherein the plurality of layers (1002) define at least one first cavity (1010); the method further comprising receiving a reinforcing material having a stiffness greater than the stiffness of the at least one frame material in the at least one first cavity (1010). 8. The method of claim 5, wherein the plurality of layers (1002) define at least one first cavity (1010); the method further comprising receiving a hardened material having a hardness greater than the hardness of the at least one structure material into the at least one first cavity (1010). 9. The method of claim 5, wherein the plurality of layers (1002) define at least one second cavity (1022) configured to reduce a weight of the structure (42) compared to a comparable structure formed without the at least one second cavity (1022). 10. The method of claim 1, wherein the method further comprises forming one or more attachment features (1004, 1006) on or adjacent to the proximal surface (42p) and configured to attach the structure (42) to the distal end of a probe fitting (20). 11. The method of claim 1, wherein the method further comprises forming the distal surface (42d) as a curved surface sized to abut a curved portion of an outer surface of a target. 12. The method of claim 1, further comprising placing a wear-resistant layer (1042) on at least a portion of the distal surface (42d). 13. The method of claim 1, further comprising forming the channel (52) to cause a fluid received from a probe fitting (20) to flow in a laminar manner from the proximal surface (42p) to the distal surface (42d). 14. The method of claim 11, further comprising placing the distal surface (42d) against one of a tube, a bar, an ingot or a track wheel. 15. The method of claim 11, further comprising placing the distal surface (42d) against a target formed from a composite material.