Single-crystal components of gas turbine engines, like turbine blades, are inspected in the installed state within the engine for cracking in certain critical areas using longitudinal ultrasonic waves. A first, rough orientation of the ultrasonic waves onto the critical area is accomplished under camera-visual control using an ultrasonic probe whose shape conforms to the respective component area and which, therefore, can be form-fitted to the component. For fine-positioning of the ultrasonic waves in the critical area, a reference signal is generated at a component-specific geometrical contour adjacent to the critical area by second ultrasonic waves emitted at a local distance to the first ultrasonic waves. The presence of this signal ensures the safe, disturbance-free detection of cracks in the critical blade area by means of longitudinal sonic waves. The invention includes an apparatus for the performance of the method.

Method and apparatus for non-destructive testing of components of gas turbine engines made of monocrystalline materials

Two ultrasonic simulation packages: Imagine 3D and SIMSCAN have specifically been developed to solve the inverse problem for blade root and rotor steeple of low-pressure turbine. The software was integrated with the 3D drawing of the inspected parts, and with the dimensions of linear phased-array probes. SIMSCAN simulates the inspection scenario in both optional conditions: defect location and probe movement/refracted angle range. The results are displayed into Imagine 3-D, with a variety of options: rendering, display 1:1, grid, generated UT beam. The results are very useful for procedure developer, training and to optimize the phased-array probe inspection sequence. A spreadsheet is generated to correlate the defect coordinates with UT data (probe position, skew and refracted angle, UT path, and probe movement). The simulation models were validated during experimental work with phased-array systems. The accuracy in probe position is ±1 mm, and the refracted/skew angle is within ±0.5°. Representative examples of phased array focal laws/probe movement for a specific defect location, are also included.

H. D. Mair

Papers

Ultrasonic simulation—Imagine3D and SimScan: Tools to solve the inverse problem for complex turbine components