Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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Improvements in detectability attainable through use of zoned ultrasonic inspection will be quantified and documented, permitting subsequent assessments by the OEMs of the effectiveness of such systems in improving the quality of titanium billet used for aircraft engine applications. Major Accomplishments and Significant Interactions: Date June 14-15, 1999 September 15, 1999 June 8-12, 2000 August 15, 2000 October 6, 2000 November 15, 2000 February 8, 2001 February 22, 2001 May 7-8, 2001 August 14, 2001 Description Technical Kick-off Meeting in West Palm Beach, FL Workshop in Ames to discuss the random defect block and other 3.1.1 planning issues. Inspection of the Random Defect Block by RMI in Niles, OH before and after modification of the surface condition, as observed by entire team. Presentation of preliminary results of the RDB recovery program to the FAA at the Semi- Annual Review Meeting in Evendale, OH.. Team discussion, with FAA, of RDB recovery program. Presentation of status of RDB recovery program at AACE Annual Symposium in Seattle, WA. Presentation of status of the RDB recovery program at the ETC Semi-Annual Review in Atlantic City, NJ. Presentation of results of the RDB recovery program and proposed future plans at ANE, Burlington, MA. Team meeting to lay out plan for restart of subtask Presentation of current status at the FAA R E&D Technical Review in Atlantic City Publications and Presentations: Date December 8, 1999 March 28, 2000 July 19, 2000 July 19, 2000 Description “Probability of Detection Determination for Internal Inclusions in Gas Turbine Engine Rotating Components”, presented by Bruce Thompson at the 4 th Annual FAA/Air Force Workshop on the Application of Probabilistic Methods to Gas Turbine Engines, Jacksonville, Florida. “Overview of S/N Based POD Methodologies”, presented by Bruce Thompson at the ASNT Spring Conference and 9 th Annual Research Symposium, Birmingham, Alabama “A Methodology for Predicting the Probability of Detection for Ultrasonic Testing”, presented by W. Q. Meeker at the Review of Progress in Quantitative Nondestructive Evaluation, Ames, Iowa. “Ultrasonic and Statistical Analyses of Hard-Alpha Defects in Titanium Alloys”, presented by C.-P. Chiou at the Review of Progress in Quantitative Nondestructive Evaluation, Ames, Iowa. October 16, 2000 “The Use of Physical Models of the Inspection in the Determination of POD”, presented by R. B. Thompson at the workshop, “POD Methodologies: New Horizons,” organized by The Technological Cooperation Program (TTCP), an international collaboration of the defense departments of English-speaking countries, in Patuxent River, Maryland. March 28, 2001 July, 2001 “Use of Physical Models of the Inspection Process in the Determination of Probability of Detection,” presented by R. B. Thompson at the ASNT Spring Conference and 10 th Annual Research Symposium, Denver, Colorado. “Use of Physical Models of the Inspection Process in the Determination of Probability of Detection,” R. B. Thompson, published in Materials Evaluation, Volume 59, Number 7, pp.861-865 (2001) Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 97
Project 3: Task 3.1: Subtask 3.1.2: Inspection Systems Capability Assessment and Validation POD Methodology Applications POD of Ultrasonic Inspection of Titanium Forgings Team Members: HW: Tim Duffy, Andy Kinney, Waled Hassan GE: Dick Burkel, Bob Gilmore, Jon Bartos, Dave Copley, Walt Bantz, Ed Nieters ISU: Thomas Chiou, Bill Meeker, Bruce Thompson, Lisa Brasche PW: Jeff Umbach, Kevin Smith, Taher Aljundi Students: none Program initiation date: June 15, 1999. All effort was stopped on March 17, 2000; On March 14, 2001, guidance was received regarding resumption of the technical work on subtask 3.1.2 with the initial activity being the revision of program schedules and technical path to account for the RDB results. Objectives: • To extend the SNR-based methodology developed in Phase I to predict the POD of naturally occurring defects in titanium, sonic-shaped forgings for commonly used ultrasonic procedures and geometries. • To further extend the POD methodology to forgings of final shape, including the prediction of POD as a function of position within the part. • To provide the OEM’s with a set of tools which they can use to implement the new methodology in internal analysis of POD of forgings by increasing the user-friendliness of the methodology software and flaw and noise response models for forging conditions. Included are improvements in speed, accuracy, range of cases treated and reduction in the amount of experimental data required. • To improve the reliability of experimental methods for detecting flaws in sonic-shaped forgings and final-shaped, machined parts by developing and validating tools which allow evaluation of the likely effect on POD of proposed changes in inspections systems and procedures such as scan plans, transducer properties, gate widths, etc. • To verify that the new methodology produces POD results which are comparable with results from existent methodologies in cases when sufficient data is available that the existent methodologies can be successfully applied and which are consistent with reasonable expectations when such data is not available. • To provide the best available estimates of titanium forging POD to the aircraft engine industry, by means of periodically updating existing estimates based on new information, as it becomes available. This will include incorporating new flaw data, and extending the POD estimates to a wider range of typical forgings geometries through use of the ISU physical models. Quarterly Report – January 1, 2002 –March 31, 2002 print date/time: 6/6/2002 - 8:39 AM – Page 98
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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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The average noise characteristics,
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Engine Titanium Consortium - Center for Nondestructive Evaluation ...

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