Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Table of Contents TASK 1.1: NICKEL-BASED ALLOY INSPECTION ............................................................................................. 2 SUBTASK 1.1.1: FUNDAMENTAL PROPERTY MEASUREMENTS FOR NICKEL BILLET ........................ 2 SUBTASK 1.1.2: INSPECTION DEVELOPMENT FOR NICKEL BILLET..................................................... 13 TASK 1.2: TITANIUM BILLET INSPECTION....................................................................................................... 20 SUBTASK 1.2.1: INSPECTION DEVELOPMENT FOR TITANIUM BILLET................................................. 20 TASK 1.3: TITANIUM FORGING INSPECTION .................................................................................................. 34 SUBTASK 1.3.1: FUNDAMENTAL PROPERTY MEASUREMENTS FOR TITANIUM FORGINGS ....................................................................................................................... 34 SUBTASK 1.3.2: INSPECTION DEVELOPMENT FOR TITANIUM FORGINGS.......................................... 54 TASK 2.1: INSPECTION DEVELOPMENT FOR ROTATING COMPONENTS ................................................... 70 SUBTASK 2.1.1: DEVELOPMENT OF UT CAPABILITY FOR INSERVICE INSPECTION .......................... 70 SUBTASK 2.1.2: EDDY CURRENT PROBE EVALUATION AND IMPLEMENTATION ............................... 70 TASK 2.2: INSPECTION DEVELOPMENT TRANSITIONS TO AIRLINE MAINTENANCE ................................ 70 SUBTASK 2.2.1: APPLICATION OF ETC TOOLS IN OVERHAUL SHOPS – EC SCANNING.................... 70 SUBTASK 2.2.2: HIGH SPEED BOLTHOLE EDDY CURRENT SCANNING............................................... 71 SUBTASK 2.2.3: ENGINEERING STUDIES OF CLEANING AND DRYING PROCESS IN PREPARATION FOR FPI ................................................................................................. 77 TASK 3.1: POD METHODOLOGY APPLICATIONS ........................................................................................... 86 SUBTASK 3.1.1: POD OF ULTRASONIC INSPECTION OF BILLETS ........................................................ 86 SUBTASK 3.1.2: POD OF ULTRASONIC INSPECTION OF TITANIUM FORGINGS ................................. 98 SUBTASK 3.1.3: POD OF EDDY CURRENT INSPECTIONS IN THE FIELD.............................................. 106 Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 1
Project 1: Task 1.1: Subtask 1.1.1: Production Inspection Nickel-based Alloy Inspection Fundamental Property Measurements for Nickel Billet Team Members: HW: Andy Kinney, Waled Hassan ISU: Frank Margetan, Bruce Thompson, Ron Roberts GE: Ed Nieters, Mike Gigliotti, Lee Perocchi, Jon Bartos, Mike Keller, Richard Klaassen, John Halase, Dave Copley PW: Jeff Umbach, Bob Goodwin, Andrei Degtyar, Harpreet Wasan Students: L. Yu Program initiation date: June 15, 1999 Objectives: • To establish the basic ultrasonic properties of nickel-based alloy billet materials (Expected to be IN718, and one or more of Waspaloy, IN901, R95, or IN100) and relevant inclusions as an appropriate foundation for selection of ultrasonic inspection approaches. • To manufacture and characterize flat bottom hole (FBH), synthetic inclusion, and real defect standards to provide data for determining defect detectability and developing improved inspections. • To improve the understanding of the relationship of defect size, shape, and composition on defect detectability in Ni alloys. Approach: Alloy Selection: Several alloys have been selected for fundamental property measurements with IN718 selected to receive the primary focus. Alloys to be considered include Waspaloy, IN100, IN901, and R95. Sample design and fabrication for properties measurements will be initiated by the team members. A list of the types of melt-related defects encountered at the billet stage in Ni-based alloys, defect morphology in the forged condition, and importance to life management will be generated by RISC. The importance of defect parameters (size, concentration, morphology, presence of voids) on detectability and life will be determined through discussion with the lifing and materials communities. Sample Fabrication: The sequence of manufacturing the properties specimens and the specimen configuration will be planned to yield as much data as possible on properties as a function of depth and orientation. Novel configurations of coupons, and sequences of coupon extraction and characterization will be considered. Sample fabrication procedures will be coordinated with the Inspection Systems Capability Working Group to ensure use by both groups The proposed billet coupon scheme is shown in Figure 1. Because backscattered noise levels are strongly dependent on details of the metal microstructure, they can be used to guide the selection of coupon locations. From low and high noise regions, a "strip" specimen will be cut along the billet Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 2
Page 1: Engine Titanium Consortium Quarterl
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 and 16: Small Diameter Billet Assessment: A
Page 17 and 18: Under normal circumstances one woul
Page 19 and 20: Plans (April 1, 2002 - June 30, 200
Page 21 and 22: Project 1: Task 1.2: Subtask 1.2.1:
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 35 and 36: Project 1: Task 1.3: Subtask 1.3.1:
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
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Project 1: Task 1.3: Subtask 1.3.2:
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possible candidates. Development wo
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Forging Calibration Standard #1 1.7
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Surface Finish Studies The plans fo
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Figure 4. Beam diameter determinati
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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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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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