Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Metrics: Assessments of the effects of microstructural anisotropy and surface curvature on inspection sensitivity for typical titanium forgings, supporting the needs of inspection development, POD estimation, and life management tasks. Comparisons of inspections using standard and optimized transducer designs, quantifying the improvement in detection sensitivity. Major Accomplishments and Significant Interactions: Date June 16, 1999 Description Technical Kick-off Meeting in West Palm Beach, FL Publications and Presentations: Date 2002 Description L. Yu, F.J. Margetan, R.B. Thompson and A. Degtyar, “Survey of Ultrasonic Properties of Aircraft Engine Titanium Forgings”, Rev. of Prog. in QNDE, Vol.21, eds. D.O. Thompson and D.E. Chimenti, (AIP, Melville NY, in press) Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 53
Project 1: Task 1.3: Subtask 1.3.2: Production Inspection Titanium Forging Inspection Inspection Development for Titanium Forgings Team Members: HW: Andy Kinney, Tim Duffy, Waled Hassan ISU: Tim Gray, Bruce Thompson, Frank Margetan, Ron Roberts GE: Dave Copley, Ed Nieters, Wei Li, Bob Gilmore, , Jon Bartos, , Richard Klaassen, Mike Keller, John Halase PW: Jeff Umbach, Bob Goodwin, Andrei Degtyar, Harpreet Wasan, Dave Raulerson Students: none Program initiation date: June 15, 1999 Objectives: • To develop a high sensitivity ultrasonic inspection of titanium forgings utilizing a 1/128” (#½) FBH calibration target, digital C-scan image acquisition, and signal-to-noise rejection criteria target without significant cost increase. • To demonstrate the new technique in a production environment over an extended period to determine its feasibility (both cost and readiness) as a production inspection. Approach: Forging Selection and Preparation: Select one representative forging design from each of the OEMs for use throughout the duration of this subtask (both inspection development and demonstration). Selection criteria will include: • forging shapes that address generic concerns such as effects of curvature, surface condition, and part thickness • forging material and microstructure • forging cost • production volume and schedule Sensitivity and coverage maps will be developed for the selected forgings using model-based tools. CAD files will be provided to ISU by each of the OEMs for the selected forging geometries. Particular attention will be given to the effect of curved surfaces on inspection sensitivity relative to flat surface sensitivity. Calibration standards will be designed to cover the range of metal travel and curvatures found on the selected forgings. Plans include two sets of standards in order to support multiple member involvement. Transducer Design Models: Fixed focus and phased array transducer design models will be reevaluated in detail to determine reasons for discrepancies between predicted and measured subsurface focused transducer behavior observed during Phase I work. This reevaluation will focus initially on assessing how well the input parameters used for the models represent the physical Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 54
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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 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 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: 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 67 and 68: phased array instruments. The desig
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Page 79 and 80: Survey of common practices (industr
Page 81 and 82: include air drying, oven drying, an
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Page 91 and 92: model parts across 17 micrograph pl
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Original Date Revised Date Descript
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Project 3: Task 3.1: Subtask 3.1.3:
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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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