Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Project 2: Task 2.2: Subtask 2.2.3: Inservice Inspection Inspection Development Transitions to Airline Maintenance Engineering Studies of Cleaning and Drying Process in Preparation for FPI Team Members: HW: Andy Kinney, James Hawkins, Tim Duffy ISU: Brian Larson, Rick Lopez, Lisa Brasche GE: Terry Kessler, Charlie Loux, Jon Bartos PW: Anne D'Orvilliers, Brian MacCracken, Kevin Smith, Jeff Stevens, John Lively Students: S. Gorman, L. Rohrhey, and Y. Wang Program initiation date: February 7, 2000 Objectives: • To establish a quantifiable measure of cleanliness including the minimum condition to allow effective inspection processing. • To establish the effect of local etching on detectability and provide guidance on best practices for removal of local surface damage from FOD and other surface anomalies. • To determine the effect of chemical cleaning, mechanical cleaning, and drying processes on the detectability of LCF cracks in titanium and nickel alloys that would be typical in field run hardware. • To update existing specifications to reflect the improved processes and provide best practices documents for use by the OEMs and airlines. Approach: The overall approach to the FPI studies is shown in the following flowchart with details provided in the text that follows. Literature and Industry Survey: The effects of cleanliness, cleaning method, and drying method on penetrant inspectability will be evaluated. As a first step, a review of the literature related to FPI processes and cleaning and drying methods will be conducted. Literature related to cleaning processes as well as NDE processes will be reviewed. Existing CASR literature review data will serve as a starting point. A survey of current practices used by the OEMs, airlines, and third party maintenance shops will be conducted to determine the existing “state of the practice”. Potential partners will be identified for participation in the follow on studies on fielded hardware. A team meeting will be held to identify the cleaning methods and drying methods to be studied and the contaminants of concern. Other organizations not participating in ETC will be invited to attend the meeting and coordination with other relevant programs will be maintained. A design of experiments approach will be considered in order to optimize the use of the results. A set of 40 specimens, 20 titanium and 20 nickel will be generated by CASR staff. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 77
Survey of common practices (industry) Survey of existing data (literature) Identify drying methods for study Identify cleaning methods for study Identify typical contaminants of concern Define and acquire crack samples for baseline studies Identify engine run hardware for use in cleanability studies Study to detemine "how clean is clean"; "how clean is needed" Use metrics established by MacCracken/ Kessler Assess methods at airline shops; compare against baseline sample Matrix of cleaning process effectivity vs contaminant Engineering study to determine effect of drying method on detectability (t and T) for oven drying flash drying and air drying Utilize lcf samples to extent possible; study on components required to address thermal mass issues Engineering study to determine effect of cleaning on detectability Potential variables: aqueous degreasers ultrasonic cleaners plastic media blast water jet blast solvent cleaners etching processes (local only) chemical cleaners vapor degreasers Utilize lcf crack samples to assess detectability; effect of cleaner on background, wetting characteristics, residual stress, etc. Matrix of drying process vs detectability Matrix of cleaning process vs detectability Develop best practices document and necessary spec changes Figure 1. Program Plan for “Engineering Studies of Cleaning and Drying Process in Preparation for FPI”. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 78
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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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Project 1: Task 1.2: Subtask 1.2.1:
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system will be at GE, and evaluatio
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fixed-focus transducers that were n
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