Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Original Revised Description Status Date Date POD for nickel billet 24 months Initiate nickel billet POD program utilizing results from Production Inspection Task. (ISU, with support from AE, GE, PW) 30 months Characterize transducers to be used in inspection of nickel billets. (Utilize results from 1.1.2) 58 months Predict response for nickel billets. Use calibration standards and chord blocks for validation as appropriate. (ISU with support from AE, GE, PW) 60 months Provide report of POD estimates for nickel billet. (ISU with support from AE, GE, PW) Compare results with those from alternative POD methodologies. (GE, with support from ISU) 60 months Report documenting the POD and PFA estimates for nickel billet, including comparison with POD results from existent methodologies. (8/97 - Phase I (12/97 - Phase I) (4/98 - Phase I) (8/98 - Phase I) Program start 6/15/99 Comparison of inspection systems - Use of the Random Defect Block Random defect block fabrication completed. ISU predictions of accuracy of model completed. Initiate ETC measurements using zoned and conventional inspection (on commercial systems. Complete measurements on RDB. (GE) Begin data analysis of ETC measurements on random defect block. (All) 5/8/00 1/8/01 Begin random defect block recovery program. Complete random defect block recovery program. 6 months TBD Incorporate interim results into provision of improved default POD curves to RISC and TRMD. (GE, PW, with support of AE) 38 months Provide report comparing conventional and zoned inspection systems in use by billet suppliers, based on data from the Random Defect Block. (All) 40 months A report documenting the relative effectiveness of conventional and Multizone systems for the ultrasonic inspection of billet. Completed. Effort initiated at program start in June 1999 Completed Expect delay resulting from RDB issues. Deliverables: A report defining a method for relating properties of naturally-occurring flaws to the parameters of the ISU model. A report assessing success of the Phase I development of a new POD methodology. Software and material characterization procedures with which the OEMs can implement the new methodology. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 95
A report documenting the relative effectiveness of conventional and Multizone systems for the ultrasonic inspection of billet. Revised estimates of POD for larger diameter titanium billet (10″ to 14″). POD and PFA estimates for nickel billet, including comparison with POD results from existent methodologies. Estimates of POD and PFA for titanium billet based on use of the random defect block, CBS data, and data reported to JETQC, including comparison with POD results from existent methodologies. Metrics: A procedure for incorporating the properties of naturally-occurring defects into a model-based POD methodology will have been defined in a formal report which becomes the basis for industrial practice, providing a consistent basis for future implementation of the POD methodology. The success of the new POD methodology developed in Phase I will be critically reviewed in terms of attainment of the original goals, using the following criteria: • POD results are more accurate than those of existing methodologies. They should be close (e.g., flaw size for a given probability within ±40%) to those from existing (R e and â-versus-a) methods when the requirements of those methods are satisfied and provide sensible predictions in cases in which the existing methods cannot produce answers. • PFA results are estimated as a function of threshold and these estimates are validated by independent experiments. • The method provides a means to predict the effect on POD and PFA of changing (as a minimum) transducer beam properties (diameter, focal length, water path, beam orientation); transducer frequency; scan index; flaw properties (location, dimensions, acoustic impedance, orientation relative to the sound beam); material properties (acoustic impedance, grain-boundary noise), with experimental validation that the response agrees with that predicted by the model, as a result of changing any one of these parameters, within accuracies typical of ultrasonic measurement, i.e., about ±3 dB (or ±40%). Modifications will be developed that will enhance the speed, simplicity of use, and range of applicability of the POD software developed in Phase I; the ease of operation will be demonstrated by successful transfer of the software to one or more OEMs. Estimates of the POD of hard-alpha defects in titanium billets will be extended to cover billet diameters up to 14″. Success of this enhanced capability for assessing the quality of one of the materials used in manufacture of aircraft engines will be indicated by incorporation of these estimates in life management calculations by the FAA, members of ETC and the Rotor Integrity Subcommittee of AIA. Estimates of the POD of hard-alpha defects in titanium billets, and of white spots in nickel billets, will be updated periodically. Success will be indicated by incorporation of these estimates in life management calculations by the FAA, members of ETC, and the Rotor Integrity Subcommittee of AIA. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 96
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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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system will be at GE, and evaluatio
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fixed-focus transducers that were n
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Back-Wall Scan FBH scan 20% 57% 49%
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63% Back-Wall Scan 74% FBH scan 58%
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Figure 6. Noise and target amplitud
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Original Date Revised Date Descript
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Objective/Approach Amendments: Obje
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(a) Transducer is: 15 MHz 0.5”-Di
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FOM (std. units) 0.20 0.18 0.16 0.1
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Peak> Range of Ave. Range of Peak G
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Page 67 and 68: phased array instruments. The desig
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Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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