Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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#1 FBH 2A Top 2A Side 1A 1B 1C 2A 2B 2C 3A 3B 3C 2A Bottom Figure 2. Sample of metallographic evaluation of FBHs. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 59
Surface Finish Studies The plans for the surface finish study have been refined during this reporting period with significant input by the three OEMs. GE has primary responsibility for this activity and will initiate the execution of the plan. While the plan is not quite finalized, the sequence of events is as follows – (1) GE has FBHs placed in the pancake, performs UT characterizing of the holes, applies the 1 st set of machining passes, acquires profiles of the machining grooves, and performs UT with specified transducers, (2) P&W performs UT inspection of the 1 st machined surface, applies the 2 nd set of machining passes, and performs UT inspection of the 2 nd machined surface, (3) GE acquires profiles of the 2 nd machined surface, and performs UT inspection of the 2 nd machined surface, (4) Honeywell performs UT inspection of the 2 nd surface, applies the 3 rd set of machining grooves, and performs UT inspection of the 3 rd surface, (5) GE performs UT inspection of the 3 rd surface finish, and acquires profiles of the 3 rd machined surface, (6) Data is analyzed by the team to relate surface finish conditions to near surface resolution and to signal to noise ratio. Hopefully, a relationship can also be established between feedrate and front surface signal ringdown. Some of the details that are yet to be worked out include identification of the transducers to be used, which feedrates to use, what is the minimum UT data that should be collected at each site, and how should the machinists requirements be controlled/recorded. Beam Properties A goal of subtask 1.3.2 is to design an inspection scheme that achieves #1/2 FBH sensitivity in Ti forgings. When designing a zoning scheme and choosing transducers, one of the key steps is to define the requirements of the ultrasonic pulse volume. It has been shown theoretically and verified experimentally that the signal-to-noise (S/N) ratio is approximately inversely proportional to the square root of the pulse volume. Thus, to meet the subtask goal, one needs to define the restrictions on the pulse volume that provide acceptable S/N ratios for a #1/2 FBH inspection. During the previous and current quarters such data was acquired at GE-QTC. Signal-to-peak-noise ratios were measured using several transducers with different focal characteristics to achieve a wide range of pulse-volume values. The measurements were performed on the highest noise “property” coupons from each OEM’s Ti 6-4 forging. Two of the three coupons had arrays of #1 FBH drilled into them, and one of the holes in the PW coupon served as a reference against which peak noise values were measured. The data acquired using an F6 transducer with the beam focused on the FBHs is shown at Figure 3. The gain was selected such that the response from #1/2 FBH would be at 80% Full Screen Height (FSH). The peak noise was measured for each of Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 60
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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
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 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: Forging Calibration Standard #1 1.7
Page 63 and 64: Figure 4. Beam diameter determinati
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Page 67 and 68: phased array instruments. The desig
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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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Page 97 and 98: A report documenting the relative e
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incorporating the results of the pr
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