new overlay penetrant inspection option to support life ... · in service inspection is often by...
TRANSCRIPT
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New Overlay Penetrant Inspection Option to
Support Life-Cycle Inspection
Ward D. Rummel
D&W Enterprises, LTD.
Littleton, Colorado, USA
Prepared for presentation to the
“The 2014 In Space Inspection Workshop”,
July 15-16 at the Gilruth Center - Johnson Space Center, in Houston, TX.
New Technology Transfer Report from P-Met High-Tech Co. Pvt. Ltd.
Gorwa, Baroda – 390 016, (Gujart) INDIA
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OVERVIEW
• LIFE CYCLE CONSIDERATIONS HAVE EVOLVED AS CRITICAL
ELEMENTS IN MODERN STRUCTURES AND SYSTEMS DESIGN AND
USE
• NONDESTRUCTIVE TESTING (NDT) CAPABILITIES ARE INTEGRAL TO
AND ARE OFTEN CRITICAL TO LIFE CYCLE ANALYSES IN SPACE
SYSTEMS AND TO SYSTEMS IN THE PUBLIC DOMAIN
• LIQUID PENETRANT IS A POPULAR METHOD USED TO ASSESS
STRUCTURAL INTEGRITY.
• THIS PRESENATION INTRODUCES A NEW METHOD OF
DOCUMENTING THE RESULTS OF A LIQUID PENETRANT
ASSESSMENT PROCESS
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STRESS
CONCENTRATION Specimen
will fail
at the
crack site
The
STATIC
CASE
• THE INITIAL STATE AND MICRO-IMPERFECTION CONTENT
• ON THE IN-SERVICE LOADING
• OPERATIONAL ENVIROMENTS
STRUCTURAL MATERIALS LIFE IS STRONGLY DEPENDENT ON:
BACKGROUND
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MATERIAL FRACTURE S
TR
ES
S L
EV
EL
CRACK SIZE
Critical Crack Size Varies with Stress Level
The
STATIC
CASE
ST
RE
SS
LE
VE
L
CRACK SIZE
ProofTest
NDI
Operating Stress
Based on NDI
Operating Stress
Based on
Proof Load
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PD
D
LIFE - CYCLES
Service Life
Start of FailuresDue to Fatigue
and crack growth
Crack Nucleation
The Dynamic Case
C
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SLOW CRACK GROWTH
INITIAL CRACK SIZE
BY NDI
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LIFE MANAGEMENT
THROW IT AWAY JUST
BEFORE IT BREAKS
DE
FE
CT
SIZ
E
Nucleation
and Linkup
Current Useful
Life
Extended
Life
Return-to-Service
Intervals
REINSPECT
No Defect
Return to Service
Defect Found
Retire from Service
NDI LIMIT
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SMALL AIRFRAME
CRACK
Crack and Fracture at
a Fastener Hole in a T-
38 Aircraft Wing
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CRACK SIZE SCREENING IS OFTEN BY NDI
AND
IS OFTEN BY THE LIQUID PENETRANT METHOD
IN SERVICE INSPECTION IS OFTEN BY
THE LIQUID PENETRANT METHOD
IN BOTH SYSTEM DESIGN AND IN LIFE
CYCLE MAINTENANCE, IT WOULD BE USEFUL
TO HAVE A RECORD ON CRACK GROWTH
A NEW METHOD OF RECORDING LIQUID
PENETRANT INDICATIONS HAS BEEN INTRODUCED
BY P-MET
IMAGES SHOWN ARE ON PROCESS CONTROL
TEST SPECIMENS THAT ARE ROUTINELY USED
TO ASSESS THE PERFORMANCE OF AN
APPLIED LIQUID PENETRANT INSPECTION PROCESS
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A TYPICAL LIQUID PENETRANT INSPECTION PROCESS
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APPLICATION OF A STRIPPABLE FILM TO RECORD RESULTS
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REMOVAL AND PRESERVATION OF THE FILM RECORD
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EXAMPLE FILMS ON
• CRACKED CHROME (SHALLOW
CRACK PANELS
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EXAMPLE FILMS ON
• IMPACT CRACKED PANELS (TAM
AND PSM)
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EXAMPLE FILMS ON
• QUENCH CRACKED ALUMINUM
PANELS
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• THE STRIPPABLE FILM OFFERS A SIMPLE PROCESS TO
RECORD LIQUID PENETRANT INSPECTION RESULTS
• IT OFFERS SOME ENHANCEMENT OF INSPECTION RESULTS
• IT IS APPLICABLE TO BOTH VISIBLE AND FLUORESCENT
PENETRANT PROCESSES
• IT IS ANTICIPATED TO BE MOST USEFUL FOR DOCUMENTING
INCREMENTAL RESULTS IN STRUCTURES TEST VALIDATIONS
AND IN DOCUMENTING AREAS WITH DIFFICULT ACCESS
• WORK REMAINS TO QUALIFY THE METHOD AND MATERIALS FOR
COMMERCIAL APPLICATIONS AND TO ASSESS THE AGING
CHARACTERISTICS OF THE FILMS
SUMMARY
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THANKS FOR SHARING
• P-Met High-Tech Co. Pvt. Ltd.
Gorwa, Baroda – 390 016,
(Gujart) INDIA
• Mr. Devendra M. Mehta, Managing
Director, and his creative employees