Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Task 2: Task 2.2 Subtask 2.2.2: Inservice Inspection Inspection Development Transitions to Airline Maintenance High Speed Bolthole Eddy Current Scanning Team Members: HW: Tim Duffy, Jim Ohm, Waled Hassan ISU: Lisa Brasche GE: Tony Mellors, Shridhar Nath, Jon Bartos PW: Kevin Smith, Dave Bryson, Rob Stephan Students: None Program initiation date: June 15, 1999 Objectives: To develop common fixtures to reduce inspection variables and arrive at a standardized inspection technique. To measure the process capability. To utilize this information to develop an industry best practice document. Approach: Evaluation of Existing Processes: Efforts will concentrate on process improvements for and standardization of high speed bolt hole scanning. A detailed evaluation of existing OEM inspection processes and needs will be conducted. Current equipment and tooling will be analyzed to provide a baseline of existing inspection processes and their limitations. The data will be analyzed for potential process improvements and identification of common tooling approaches. A survey of available commercial tooling will be included as part of the assessment and included in the baseline as possible. Development of Common Tooling: The efforts will then be focused on the detailed design and fabrication of common tooling with an emphasis placed on variability reduction and defect detectability improvements. An inspection demonstration will be conducted on a sample set of hardware from each of the industrial members for validation of process development. A comparison to the baseline data will be made. Working with task 3.1.3 an evaluation of the process POD will be conducted on existing bolt hole reliability specimens. Development of Common Process: A common inspection technique and best practices document will be developed. Currently AS4787, Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine Hardware, serves as a standard for hole inspection. This document will be revised to reflect the results of the ETC effort. Recommendations for equipment improvements will be supplied to vendors and implications for further study will be provided to the FAA. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 71
Objective/Approach Amendments: Objective and approach remain as originally proposed in July 1998. Progress (January 1, 2002 – March 31, 2002): The subtask was realigned during this quarter. A revised plan was generated and is reflected in the “Milestones” section below. The technical team supporting this subtask held several conference calls leading to significant technical progress . The following represents a summary of the accomplishments: Bolt hole Simulator Design: The design of the bolt hole simulator is complete. This piece will be used to precisely fixture round bolt hole specimens (see Figure 1) in a circular layout as they would be for a typical rotating engine component. This piece will be able to hold twenty-five 1.875” diameter specimens having a 0.250-inch thickness. The bolt hole diameter within these circular specimens will be 0.460 inches. The layout aligns the specimens in a precise circular pattern with the bolt holes within 0.002 inches of geometric center. When specimens are aligned, they can be locked into position to prevent rotation and lift-out during scanning. Probe Translation Device: A preliminary design is complete. This device is required to precisely position and translate a rotating eddy current probe through boltholes of various diameters in critical engine rotating hardware. These probes will be mounted to off-the-shelf high-speed eddy current bolt hole rotating drivers and are used for detecting cracks along the length of the bolt holes. There are various probe-rotating drivers available and the device is designed to be able Figure 1. FML100146 Eddy Current Bolt hole Crack Specimen Design. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 72
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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
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1.2 1.0 0.8 V-DIE-A coupon "D" (axi
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Attenuation (dB/in) . Waspalloy Att
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Deliverables: Fundamental propertie
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Small Diameter Billet Assessment: A
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Under normal circumstances one woul
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Plans (April 1, 2002 - June 30, 200
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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%
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Page 33 and 34: Original Date Revised Date Descript
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Page 39 and 40: (a) Transducer is: 15 MHz 0.5”-Di
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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 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 103 and 104: Milestones: Revised dates of TBD ar
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