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E-raamat: Development of a 2D Ultrasonic Array Inspection for Single Crystal Turbine Blades

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  • Sari: Springer Theses
  • Ilmumisaeg: 30-Oct-2013
  • Kirjastus: Springer International Publishing AG
  • Keel: eng
  • ISBN-13: 9783319025179
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Development of a 2D Ultrasonic Array Inspection for Single Crystal Turbine BladesSuurem pilt
  • Formaat: PDF+DRM
  • Sari: Springer Theses
  • Ilmumisaeg: 30-Oct-2013
  • Kirjastus: Springer International Publishing AG
  • Keel: eng
  • ISBN-13: 9783319025179
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Recognized as an outstanding addition to the literature, this publication describes a novel technique that meets a core industrial inspection requirement in a high-value component in jet engines. The coverage includes production specifications and trial data.



This thesis describes the development of a new technique to solve an important industrial inspection requirement for a high-value jet-engine component. The work – and the story told in the thesis – stretches all the way from the fundamentals of wave propagation in anisotropic material and ultrasonic array imaging through to device production and site trials. The book includes a description of a new method to determine crystallographic orientation from 2D ultrasonic array data. Another new method is described that enables volumetric images of an anisotropic material to be generated from 2D ultrasonic array data, based on measured crystallographic orientation. After extensive modeling, a suitable 2D array and deployment fixtures were manufactured and tested on in situ turbine blades in real engines. The final site trial indicated an order of magnitude improvement over the best existing technique in the detectability of a certain type of root cracking.

The Development of a 2D Ultrasonic Array Inspection for Single Crystal Turbine Blades should be an inspiration for those starting out on doctoral degrees as it shows the complete development cycle from basic science to industrial usage.

1 Introduction
1(12)
1.1 Motivation
1(2)
1.2 Thesis Objectives and Background
3(7)
1.2.1 Single Crystal Turbine Blades
3(4)
1.2.2 NDE and the Inspection of Turbine Blades
7(2)
1.2.3 Ultrasonic Phased Array Inspections
9(1)
1.2.4 Anisotropy of Single Crystals
10(1)
1.3 Thesis Outline
10(3)
References
11(2)
2 Wave Propagation in Anisotropic Media
13(28)
2.1 Introduction
13(2)
2.2 Bulk Waves in Anisotropic Solids
15(12)
2.2.1 Bulk Wave Propagation in Isotropic and Anisotropic Solids
15(1)
2.2.2 Phase and Group Velocity
16(3)
2.2.3 Analytical Models
19(5)
2.2.4 Results and Validation
24(3)
2.3 Wave Amplitude from a Point-Force on an Infinite Half-Space
27(11)
2.3.1 Analytical Model
28(7)
2.3.2 Results and Validation
35(3)
2.4 Summary
38(3)
References
39(2)
3 Imaging Anisotropic Components with Ultrasonic Arrays
41(22)
3.1 Introduction
42(1)
3.1.1 Ultrasonic Array Imaging Algorithms
42(1)
3.1.2 The Ultrasonic Inspection of Anisotropic Materials
43(1)
3.2 Anisotropic TFM Algorithm
43(2)
3.3 Effect of Velocity Variation
45(5)
3.3.1 Simulated Data
46(1)
3.3.2 Experimental Data
47(3)
3.4 Effect of Beam Profile Variation
50(6)
3.4.1 Simulated Field Patterns
51(3)
3.4.2 Experimental Results
54(2)
3.5 Effect of Crystallographic Misorientation
56(4)
3.5.1 Simulations with the Linear Array
56(3)
3.5.2 Experiments with the 2D Array
59(1)
3.5.3 Discussion on Crystallographic Misorientation
60(1)
3.6 Summary
60(3)
References
61(2)
4 Crystallographic Orientation Using Ultrasonic Arrays
63(18)
4.1 Introduction
63(3)
4.1.1 X-Ray Diffraction Orientation
64(1)
4.1.2 Ultrasonic Orientation
64(2)
4.2 Velocity Profile Measurement Methods
66(9)
4.2.1 Bulk Wave Methods
67(1)
4.2.2 Surface Wave Method
68(1)
4.2.3 Orientation Accuracy
69(6)
4.3 Image-Based Method
75(4)
4.3.1 Orientation Accuracy
76(3)
4.4 Summary
79(2)
References
79(2)
5 The Development of an in Situ Ultrasonic Array Inspection System
81(22)
5.1 Introduction
81(2)
5.1.1 Inspection Specification and Strategy
82(1)
5.2 The Development of the Probe Deployment and Manipulation System
83(1)
5.3 The Design of the Ultrasonic Array Probe
84(6)
5.3.1 General Ultrasonic Array Design Considerations
84(1)
5.3.2 Initial Ultrasonic Array Experiments
85(3)
5.3.3 Design of the in Situ Engine Probe
88(1)
5.3.4 Crystallographic Orientation Considerations
89(1)
5.4 Ultrasonic Array Probe Performance
90(10)
5.4.1 Corrected TFM Images
91(1)
5.4.2 Effect of Beam Amplitude
92(2)
5.4.3 Effect of Crystallographic Orientation on Defect Detection
94(2)
5.4.4 Effect of Defect Size and Orientation
96(1)
5.4.5 Crystallographic Orientation Accuracy
97(3)
5.5 Discussion
100(3)
References
101(2)
6 The Assessment of the Developed Inspection Capability
103(8)
6.1 Introduction
103(2)
6.2 Raw Inspection Results
105(1)
6.3 Probability of Detection Results
106(2)
6.4 Capability of the Single Element Probe
108(1)
6.5 Concluding Remarks
109(2)
References
110(1)
7 Conclusion
111(6)
7.1 Findings of Thesis
111(3)
7.2 Suggested Future Work
114(3)
7.2.1 3D Arrays
114(1)
7.2.2 Ultrasonic Crystallographic Orientation Methods
114(1)
7.2.3 Improved Defect Characterisation in Anisotropic Materials using Large Aperture Arrays
114(1)
7.2.4 FMC Data Simulations of Complex Defects
115(1)
7.2.5 Alternative Imaging Algorithms
115(1)
References
116(1)
Appendix A The Wave Energy Approach for Computing Group Velocity 117(4)
Appendix B Analysis of Finite Element Accuracy for Beam Amplitude Modelling 121(4)
Appendix C The Gaussian Curvature of a Surface 125(2)
Appendix D The Development of a Single Element Probe for the Inspection of Turbine Blades 127(2)
Appendix E Probability of Detection 129
Dr. Christopher Lane, currently at Rolls-Royce plc UK, earned his Engineering Doctorate from the University of Bristol. He won the Universitys Faculty of Engineering prize for best research degree thesis in 2012. He was also awarded the Rolls-Royce the John Bush Award for outstanding technical achievement by a young engineer, and the Royal Aeronautical Society Young Persons Achievement Award.
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