Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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focusing with respect to the scale of the microstructure on the form of the signal and noise distributions, and the rules required to determine the distribution of signal-in-the-presence-of-noise from the noise distribution and the flaw free noise response. All of these will be considered as influenced by the presence of anisotropy and beam modification by the part geometry. Results of these software and procedural advances will be integrated and provided to the OEMs for their internal use. These uses are anticipated to include life management calculations, such as consideration of the likely effects on POD of proposed changes in inspection systems and procedures such as scan plans, transducer properties, gate widths, etc. POD for Titanium Forgings: Efforts to acquire naturally occurring hard alpha inclusion data will be continuously made. Possible sources include field and manufacturing finds, the utility of which will depend on the degree to which appropriate procedures are utilized to fully characterize the 3-D shapes of these finds. Information gained during the forging studies of the TRMD program will also be used. This information will be used, as appropriate, to provide POD estimates. The methodology will be used to evaluate the improvements in POD afforded by developments of the Production Inspection Task 1.3.2. Objective/Approach Amendments: Objective and approach remain as originally proposed in July 1998. Progress (January 1, 2002 – March 31, 2002): On March 16, 2000 the FAA issued instructions to end all expenditures on Task 3, other than those associated with the RDB technical plan, with a restart to be considered once the sources of the discrepancy had been resolved. Hence the vast majority of the work on this task was terminated. A low level of effort has continued with the objective of coordinating with the Production tasks the work that is needed to support the POD effort. This had the objectives of ensuring that the fundamental studies measurements would produce the information needed by the POD group and that forging samples being produced would support the POD methodology. To these ends, the progress of the fundamental studies and forgings tasks have been monitored in terms of findings such as the degree of anisotropy and inhomogeneity of noise that has been observed in billet and forging materials and plans to prepare samples that will provide information to be used in POD assessment. In the latter context, particular attention has been paid to the fabrication of a forging containing synthetic hard-alpha inclusions and flat bottom holes. On March 14, 2001, the FAA indicated that work is to be resumed on sub-tasks 3.1.1 and 3.1.2, and planning for that restart initiated. Plans (April 1, 2002 – June 30, 2002): Planning of the restart of subtask 3.1.2 will take place after the completion of the planning for restart of subtask 3.1.1. In the meantime, continued interactions with the Fundamental Studies and Production Tasks will occur, with the initial effort focused on the design of the forging POD sample. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 101
Milestones: Revised dates of TBD are shown for most of the tasks, given that work has been stopped while the problems with the random defect block are being addressed. Original Date Revised Date Description Status Application of the Methodology to Sonic-Shaped Forgings: 12 months TBD White-paper defining a method for predicting POD for sonic-shaped forged parts. 18 months Complete scanning and analysis of blocks of forged material with FBH and SHA flaws. (ISU with support of AS) 22 months Investigate the application of Phase I methodology to the scan data on forged material with FBH and SHA flaws. (ISU) 24 months Initiate generalization of the POD methodology to apply to sonic-shaped forgings. (ISU with support from GE) 27 months Define experimental plan for use of FBH and SHA sonic-shaped forged samples available from TRMD and Phase II Production Inspection Task. (All) 27 months Report documenting a method for predicting POD for sonic-shaped forged parts. 30 months Acquire data from available FBH and SHA sonic-shaped forged samples to generate noise and signal plus noise distributions. (PW, AS, GE) 32 months Complete necessary modeling and supply model predictions corresponding to data available from sonic-shaped forged samples. (ISU with support from AS) Utilize sonic-shaped forging scan data to define noise distribution. (GE, PW with support from ISU) 32 months Report documenting the revisions to the noise and flaw modeling developed in this subtask and supply the modified model predictions. 36 months Utilize sonic-shaped forging scan data to estimate the flaw-signal distribution and to compare with model prediction to define the deviation distribution. Apply the generalized methodology to estimate POD of synthetic hard alpha inclusions. (ISU with support from GE, PW) Compare with ahat vs. a and the R e methods. (GE with support from PW) 36 months Report assessing the adequacy of POD predictions of the physical/statistical model-based methodology developed in this program, based on comparison Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 102
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Engine Titanium Consortium Quarterl
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Project 1: Task 1.1: Subtask 1.1.1:
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findings for the first billet studi
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measured P(L) curve, and tabulate t
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1.2 1.0 0.8 V-DIE-A coupon "D" (axi
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Attenuation (dB/in) . Waspalloy Att
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Deliverables: Fundamental propertie
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Small Diameter Billet Assessment: A
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Under normal circumstances one woul
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Plans (April 1, 2002 - June 30, 200
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system will be at GE, and evaluatio
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fixed-focus transducers that were n
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Back-Wall Scan FBH scan 20% 57% 49%
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63% Back-Wall Scan 74% FBH scan 58%
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Figure 6. Noise and target amplitud
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Original Date Revised Date Descript
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Objective/Approach Amendments: Obje
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(a) Transducer is: 15 MHz 0.5”-Di
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FOM (std. units) 0.20 0.18 0.16 0.1
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Peak> Range of Ave. Range of Peak G
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The average noise characteristics,
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Noise C-scans through the “Flat S
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4.0” Convex Block; Flat Side Insp
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