Engine Titanium Consortium - Center for Nondestructive Evaluation ...

Small Diameter Billet Assessment: Assessment of small diameter inspection will also be completed
by Honeywell. Honeywell will perform studies using billets of < 8” diameter The objective will be to
apply technology developed in Phase II for larger Ni billet to improve nickel billet inspection in the
stated diameter of interest to small engine manufacturers. Feasibility demonstration will be
conducted in the laboratory environment using small nickel alloy billet and multizone transducers
developed for the smallest of the large diameter billets. Sensitivity analysis (#FBH) will be
conducted for various small diameter billets. A comparison will be made with the standard
spherical focus approach. Results will be provided to the Inspection Systems Capability Working
Group to allow POD estimates.
Baseline Assessment: Inspection development will be performed with the calibration standards
using existing multizone transducers to occur at PW and GE facilities to ensure hands-on
involvement by the parties responsible for final implementation recommendations. Scans and
associated measurements will be used to determine the focal depth of each transducer, measure
the axial beam profile and beam cross-section, and compare these results to model predictions.
Signal-to-noise ratio will be determined for the FBH targets. The need for new transducers will be
evaluated based on these scans and model results. New transducers will be designed and built if
results indicate that the existing transducers do not produce a focal zone at the required depth or of
the required beam diameter, and if modeling indicates that significant improvement could be
obtained by re-design. Additional funding will be sought for transducer fabrication at that time if the
team agrees that the proposed benefits are substantial.
Laboratory Demonstration: After inspection development for each alloy is completed, a laboratory
demonstration of billet inspections with optimized transducers will be provided for the ETC
members. Sensitivity to #1FBH in INCO718 and to #2.5FBH in Waspaloy will be demonstrated and
plans made for pilot inspection.
Factory Demonstration: A factory pilot inspection of approximately 100,000 pounds will be planned
to determine the sensitivity level that can be consistently achieved in production and to identify any
barriers to implementation. The first step will be for the team to identify an industry partner(s) to
perform the pilot inspection, much as RMI worked with the consortium in Phase I in the inspection
of titanium billet. A detailed plan will identify the particular specifications of INCO718 to be
inspected, i.e., VIM/VAR and/or VIM/ESR/VAR, and the number of material suppliers.
Investigations performed in the nickel fundamental studies Task 1.1.1, will provide information to
determine the need to include two types of INCO718 in the pilot inspection. If the defect types
found in the two materials and the ultrasonic characteristics are the same, then there will not be a
need to include both in the factory pilot inspection. The extent of inclusion of Waspaloy will also be
planned. Procedures for inspection, evaluation of data, and investigation of indications will be
defined. It is expected that eight finds will be cut-up and evaluated using a process similar to that
described in AC 33.15. It is expected that each OEM will participate in the destructive
characterization of indications with two planned for Waspaloy and six planned for IN718. The team
will also agree on parameters needed to determine the cost impact of implementing the higher
sensitivity inspection as compared to conventional inspection. The pilot lot evaluation of 100,000
pounds of billet with the optimum transducers will occur in cooperation with a multizone inspection
source and nickel alloy material suppliers. Evaluation of 5 to 10 heats of material is expected.
Quarterly Report – January 1, 2002 –March 31, 2002
print date/time: 6/6/2002 - 8:39 AM – Page 14