Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Since application of multizone technique is expected to be more straightforward for INCO718, most of the pilot work will be performed with that alloy. The application of #2.5FBH sensitivity to Waspaloy is expected to be more complex but an inspection technique should be ready to substitute for the last 25% of the pilot lot. The data will be evaluated and reported. Results of the pilot inspection and of any cut-ups will be provided to Task 3.1.1 for use in developing POD estimates for nickel billet. Cost and detection sensitivity assessments necessary for life management and implementation decisions will be gathered. Components of cost assessment will have been agreed on by the team and will likely include such items as system cost, longevity of equipment, recurring equipment costs, daily operational/inspection costs, and costs associated with false calls. In conjunction with the pilot lot inspection, a demonstration of the higher sensitivity inspection for INCO718 and Waspaloy will be presented to the OEMs and industry. A final report in the required FAA format will be provided. Objective/Approach Amendments: Objective and approach remain as originally proposed in July 1998. Progress (January 1, 2002 – March 31, 2002): Several consortium conference calls were conducted during the quarter to discuss the details of the subtask. A number of technical issues were discussed and decisions reached. The technical issues and discussions are summarized into two primary areas, (1) Pilot Billet Inspection, and (2) Waspaloy Standard and discussed separately below. Nickel Billet Pilot Inspection A request was forwarded to a production facility to bid on the multizone inspection of 75,000 lbs. of Inconel and 25,000 lbs. of Waspaloy. The ETC will purchase the multizone inspection of this 10- inch diameter material calibrating on the Nickel standards developed earlier. During this pilot program the ETC will purchase a select number of indications found with multizone with preference given to those that were not rejected with conventional inspection and perform ultrasonic and metallographic characterization for POD studies and future inspection implementation decisions. As soon as the purchase order is in place the Inconel standard will be sent to the production site. Waspaloy Standard At the laboratory demonstration last quarter, the Waspaloy standard was found to have some surface irregularities that prompted a more detailed investigation. Surface metrology data revealed a periodic surface irregularity with amplitude of about 5 mils and consisting of 27 cycles around the circumference of the standard. Figure 1 shows the surface metrology data taken with a dial indicator around the circumference. The two major lobes are a result of the axial split line running through the center of the standard and were expected in the measurement. To evaluate the ultrasonic impact of this surface condition, a zone 5 transducer was used to create a C-scan of the machined surface on the interior of the billet standard. Figure 2 shows these surfaces highlighted in red. The resultant C-scan in Figure 3 shows the significant amplitude variation on the inner backwall caused by the surface irregularities. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 15
Under normal circumstances one would expect the C-scan image to show fairly uniform amplitude around the circumference indicating that the sound intensity was consistent. The fluctuating intensity seen on the C-scan is at the same frequency as the surface irregularities. ISU also modeled the effects of the surface on the ultrasonic signal and produced the graph in Figure 4. This study convinced the team to pursue having the Waspaloy standard machined or polished to remove the surface condition prior to using at the production site. Waspaloy Std. Surface Profile 50 Mils (1/1000 inch) 40 30 20 10 0 -10 0 100 200 300 400 Degrees Figure 1. Surface Profile of Waspaloy Standard 27 peaks and valleys. Figure 2. Diagram of Waspaloy standard highlighting inspection surface in red. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 16
Page 1 and 2: Engine Titanium Consortium Quarterl
Page 3 and 4: Project 1: Task 1.1: Subtask 1.1.1:
Page 5 and 6: findings for the first billet studi
Page 7 and 8: measured P(L) curve, and tabulate t
Page 9 and 10: 1.2 1.0 0.8 V-DIE-A coupon "D" (axi
Page 11 and 12: Attenuation (dB/in) . Waspalloy Att
Page 13 and 14: Deliverables: Fundamental propertie
Page 15: Small Diameter Billet Assessment: A
Page 19 and 20: Plans (April 1, 2002 - June 30, 200
Page 23 and 24: system will be at GE, and evaluatio
Page 25 and 26: fixed-focus transducers that were n
Page 27 and 28: Back-Wall Scan FBH scan 20% 57% 49%
Page 29 and 30: 63% Back-Wall Scan 74% FBH scan 58%
Page 31 and 32: Figure 6. Noise and target amplitud
Page 33 and 34: Original Date Revised Date Descript
Page 37 and 38: Objective/Approach Amendments: Obje
Page 39 and 40: (a) Transducer is: 15 MHz 0.5”-Di
Page 41 and 42: FOM (std. units) 0.20 0.18 0.16 0.1
Page 43 and 44: Peak> Range of Ave. Range of Peak G
Page 45 and 46: The average noise characteristics,
Page 47 and 48: Noise C-scans through the “Flat S
Page 49 and 50: 4.0” Convex Block; Flat Side Insp
Page 51 and 52: % FSH Noise Measurements from flat
Page 53 and 54: Original Revised Description Status
Page 57 and 58: possible candidates. Development wo
Page 59 and 60: Forging Calibration Standard #1 1.7
Page 61 and 62: Surface Finish Studies The plans fo
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Page 65 and 66: size was adequate to support a 0.04
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phased array instruments. The desig
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Original Date Revised Date Descript
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Task 2: Task 2.1: Subtask 2.1.1: In
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Objective/Approach Amendments: Obje
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Figure 2. A preliminary design of t
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Publications and Presentations: Dat
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Survey of common practices (industr
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include air drying, oven drying, an
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aluminum oxide blasting is conceali
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Project 3: Task 3.1: Subtask 3.1.1:
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the methodology. These may be thoug
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model parts across 17 micrograph pl
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Z Y X Figure 4. Angle View of Void
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A report documenting the relative e
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naturally occurring flaws in forgin
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Milestones: Revised dates of TBD ar
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7a-7l 6 8 9 10 Key additional ingre
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incorporating the results of the pr
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