Joachim Bamberg

Thermographic crack detection by eddy current excitation

Eddy current thermography is a new NDT-technique for the detection of cracks in electroconductive materials. It combines the well established inspection techniques eddy current testing and thermography. The advantage of this method is to use the high performance of eddy current testing without the known problem of the edge effect. Especially for components of complex geometry this is an important factor which may overcome the increased expense for inspection set-up. The principle of this technique and an algorithm to increase the sensitivity for small defects are described. Some inspection examples on aero engines parts are presented which show the potential of eddy current thermography.

NEAR‐SURFACE RESIDUAL STRESS‐PROFILING WITH HIGH FREQUENCY EDDY CURRENT CONDUCTIVITY MEASUREMENT

The lifetime of aero engine components can be extended by applying an additional strain to the material. Typical aero engine‐alloys like Nickel‐Base superalloys or Titanium alloys can be surface‐treated by use of shot peening to induce the compressive strain near the surface. However, in order to use the additional life for critical aero engine components, a quantitative determination of strain gradients near the surface has to be carried out periodically. We propose to measure the depth‐profile of residual stresses non‐destructively by use of high frequency eddy current techniques. This paper presents results obtained with an experimental set‐up based on a high precision impedance analyzer. Test samples prepared from IN718 by shot peening of different intensities can be easily distinguished. By sweeping the frequency from 100 kHz up to 100 MHz a depth profile for the electrical conductivity from 50 μm to 500 μm can be obtained. The measured conductivity profile is a resultant from residual stresses, cold...

Refraction computed tomography

Abstract For the first time metal matrix composites have been investigated by 3D computed tomography combined with enhanced interface contrast due to X-ray refraction. The related techniques of refraction topography and refraction computed tomography have been developed and applied during the last decade to meet the actual demand for improved non-destructive characterization of high performance composites, ceramics and other low-density materials and components. X-ray refraction is an optical effect that can be observed at small scattering angles of a few minutes of arc as the refractive index n of X-rays is nearly unity (n = 1 − 10−6). Due to the short X-ray wavelength, the technique determines the amount of inner surfaces and interfaces of nanometer dimensions. The technique can solve many problems in understanding micro and sub microstructures in materials science. Applying 3D refraction computed tomography, some questions could be clarified for a better understanding of fatigue failure mechanisms under cyclic loading conditions.

Ultrasonic online monitoring of additive manufacturing processes based on selective laser melting

Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows to manufacture components by localized melting of successive layers of metal powder. In order to be able to describe and to understand the complex dynamics of selective laser melting processes more accurately, online measurements using ultrasound have been performed for the first time. In this contribution, we report on the integration of the measurement technique into the manufacturing facility and on a variety of promising monitoring results.

Process monitoring of additive manufacturing by using optical tomography

Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim stru...

Overview of additive manufacturing activities at MTU aero engines

Additive Manufacturing (AM) is a promising technology to produce parts easily and effectively, just by using metallic powder or wire as starting material and a sophisticated melting process. In contrast to milling or turning technologies complex shaped and hollow parts can be built up in one step. That reduces the production costs and allows the implementation of complete new 3D designs. Therefore AM is also of great interest for aerospace and aero engine industry. MTU Aero Engines has focused its AM activities to the selective laser melting technique (SLM). This technique uses metallic powder and a laser for melting and building up the part layer by layer. It is shown which lead part was selected for AM and how the first production line was established. A special focus is set on the quality assurance of the selective laser melting process. In addition to standard non-destructive inspection techniques a new online monitoring tool was developed and integrated into the SLM machines. The basics of this techn...

On- and offline ultrasonic characterization of components built by SLM additive manufacturing

Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows for manufacturing components by localized melting of successive layers of metal powder. In this contribution, we report on investigations in view of the influence of the process parameter ‘laser power’ on the microstructure of the manufactured component. It turned out that the online recorded A-scans allow inferring conclusions about the quality of the SLM process. We also report on offline measurements which have been performed to support the online results.

Third Order Elastic Constants and Rayleigh Wave Dispersion of Shot Peened Aero-Engine Materials

Aero-engine components exposed to high mechanical stresses are made of high-strength alloys and additionally, they are surface treated by shot peening. This process introduces compressive residual stress into the material making it less sensitive to stress corrosion cracking and fatigue and therefore benefits the components performance and lifetime. Moreover cold work is induced in an amount depending on the peening parameters. To approximate the remaining lifetime, a quantitative, non-destructive method for stress assessment is required. It was shown that surface treatment of such alloys can be characterized by broadband Rayleigh wave dispersion measurements. However, the relative contributions of residual stress and cold work, respectively, remained an open point. This paper presents the determination of third order elastic constants (TOEC) for IN718 and Ti6246, providing, together with a model for the inversion of dispersion data, a quantitative access to the acoustoelastic effect. Finally, some measurements of differently treated samples are given.

CHARACTERIZATION OF SURFACE TREATED AERO ENGINE ALLOYS BY RAYLEIGH WAVE VELOCITY DISPERSION

In aero engines mechanically high stressed components made of high‐strength alloys like IN718 and Ti6Al4V are usually surface treated by shot‐peening. Other methods, e.g. laser‐peening, deep rolling and low plasticity burnishing are also available. All methods introduce compres‐sive residual stress desired for minimize sensitivity to fatigue or stress corrosion failure mechanisms, resulting in improved performance and increased lifetime of components. Beside that, also cold work is introduced in an amount varying from method to method. To determine the remaining life time of critical aero engine components like compressor and turbine discs, a quantitative non‐destructive determination of compressive stresses is required. The opportunity to estimate residual stress in surface treated aero engine alloys by SAW phase velocity measurements has been re‐examined. For that original engine relevant material IN718 has been used. Contrary to other publications a significant effect of the surface treatment to the so...

Ultrasonic evaluation of residual stresses in aero engine materials using bulk and Rayleigh surface waves

The evaluation of residual stresses using ultrasound can be a very complex issue, because different material properties may effect the propagation of ultrasonic waves. Nevertheless, in the manufacturing of modern aero engines it is essential to benefit from the full potential of the employed materials. In this context, it is indispensable to test whether ultrasonic stress measurement is applicable for the highly developed nickel- and titanium-based alloys. This contribution contains basic investigations on the achievable measurement effect in samples made of Inconel IN718 and the Titanium alloy Ti 6-2-4-6. Furthermore, we give an overview over the principles of ultrasonic stress measurement using bulk and Rayleigh waves and present first results which are discussed with respect to texture effects and future work.