Advances in automated high throughput fan beam CT for ... · NDT in Aerospace: 11th European...
Transcript of Advances in automated high throughput fan beam CT for ... · NDT in Aerospace: 11th European...
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Imagination at work.
Jens Lübbehüsen, Radiography Sales Manager Aerospace Europe11th ECNDT, Prague/CZ, October 8, 2014
Advances in automated high throughput fan beam CT forDICONDE-conform multi-wall turbine blade wall thicknessinspection and 3D additive manufactured aerospace partCT inspection
11th European Conference on Non-Destructive Testing (ECNDT 2014), October 6-10, 2014, Prague, Czech Republic
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Outline
fan beam CT inspection of multi-wall turbine blades
cone beam CT inspection in additive manufacturing
applications & solutions
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Outline
fan beam CT inspection of multi-wall turbine blades
cone beam CT inspection in additive manufacturing
applications & solutions
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MAI AIPT MembersUSAF-AFRL
Airframe Builders
Aerospace Engine OEMs
Casting Producers
Digital Equipment Manufacturers
This presentation has been cleared and authorized for public distribution under case number 88ABW-2010-3727
Metals Affordability Initiative - MAICR/DR Impl. Consortium: Member Companies
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Metals Affordability Initiative (MAI) MAI Affordable CT Program
Technology driver:Engine performance requirements become more stringent. High performance engines utilize cooling schemes with advanced multi-wall casting technology
Inspection problem:State of the art measurement technologies (UT) are not capable of determining the acceptability of these new multi-wall castings
Conclusion:The advances in turbine engine component design (multi-wall blades) drive a clear need for CT technology. Image of simulated PITv2 blade with
artificial multi-wall structures
FOR GE internal use ONLY
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MAI Program Objectives
Accurate and repeatable - compliance with MAI Affordable Guidelines, demonstrate measurement capability of +/- 5% or 0.001 inch
Efficient – up to 30 parts/hour (up to 10 CT slices per part)
Data integrity and security – DICONDE and link to long-term image archiving solution for 2D images and slices
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System Overview – External View
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System Overview - Configuration
X-ray source:ISOVOLT Titan 450M2/0.4-1.0HP
Detector:GE “Jupiter” LDA Detector with 100 micron pixel pitch
Manipulator:SCARA Robot - Adept Cobra S600 robot
Software:GE Platform Architecture – acquisition, review, reconstruction and workflow
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System Overview – Internal View
GE Jupiter LDA
450M2/0.4-1.0HP
ISOVOLT Titan 450
IQI fixture
Part loading fixture
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System Overview – Cut-Aways
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System Overview – Cut-Aways
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Inspection Envelope
Part Height:190 mm (7.48 in)
Part Diameter:~150mm (5,9 in)* Limited by detector width
Weight:2.0 kg (4.40 lb) at full speed
190mm
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Workflow – Wall ThicknessStart
Load part tub 2with max. 25 Blades outside the cabinet
Open Sliding door manually
Change part tub 1 with part tub 2
Close Sliding door by
manually
Manual input of the Blade ID´s
( Hand scanner)
Load Blade n.. back to part tub
Grip Blade n.. with Robot
X-Ray Inspection defined Positions /
Blade
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Workflow – Wall Measurement
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Workflow – 2D with Spot Check CTStart
Load part tub 2with max. 25 Blades outside the cabinet
Open Sliding door manually
Change part tub 1 with part tub 2
Close Sliding door by
manually
Manual input of the Blade ID´s
( Hand scanner)
Define optional CT slice measurements
with Rhythm
Grip Blade n.. with Robot
Load Blade n.. back to part tub
X-Ray Inspection defined Positions /
Blade
Load Blade n.. back to part tub
Grip Blade n.. with Robot
X-Ray Inspection defined Positions /
BladeOptional
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System Capabilities - Preliminary
Used fan beam calibration artifact described in MAI guidelines document. 3 cylindrical holes of 8, 10, 12 mm diameter.
Process: CT scan at given vertical positionMeasure circle diameters, distances between circles. Correspond to probing error size and length measurement error.
Compare results to DKD (NIST equiv.) calibration report, CMM measurements.
Apply correction factor to system if necessary.
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System Capabilities - Preliminary
Measured Nominal Difference Distance measured Nominal Difference(mm) (mm) (mm) (mm) (mm) (mm)
8.0114 8.0095 0.0019B8-B10 24.2652 24.2699 0.004710.0033 10.0027 0.0006B8-B12 25.9846 25.9816 0.003012.0046 12.0015 0.0031B10-B12 24.2727 24.2663 0.0064
Probing error size 0.0019
Length measurement error 0.0047
Sum probing error plus length measurement error0.0066mm
Temperature12:22pm 24.6C
Preliminary System ResultsLength measurement error < 5 µmProbing error < 2 µmTotal error < 7 µm
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Technical Design Approach Hardware
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Outline
fan beam CT inspection of multi-wall turbine blades
cone beam CT inspection in additive manufacturing
applications & solutions
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Excursus: CT for Additive Manufacturing
Utilized principle: SLS – selective laser sintering
Sources: Wikipedia, Concept Laser
Used manufacturing device:
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Additive Manufacturing – example for CT analysis
Product:
Additive manufacturedworkpiece
Material:
TiAl6V4
Dim (LxWxH):
100x55x30 mm
By courtesy of
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Additive Manufacturing – example for CT analysis
Inspection Task:
Defect analysis
Porosities, inclusions, cavities
Dimensional analysis
Wall thickness,
CAD comparison
By courtesy of
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Additive Manufacturing – example for CT analysis
U = 260 kV
I = 550 µA
Vx = 100 µm
F: 1 mm Sn
Used µCT system:
v|tome|x
m 300
By courtesy of
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Additive Manufacturing – example for CT analysis
3D image:
renderedsurface
Used µCT system:
v|tome|x m 300
By courtesy of
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Additive Manufacturing – example for CT analysis
2D slices and3D image
Used µCT system:
v|tome|x m 300
By courtesy of
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Additive Manufacturing – example for CT analysis
3D image:
porosityanalysis
Used µCT system:
v|tome|x m 300
By courtesy of
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Additive Manufacturing – example for CT analysis
3D image:
wall thicknessanalysis
Used µCT system:
v|tome|x m 300
By courtesy of
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Outline
fan beam CT inspection of multi-wall turbine blades
cone beam CT inspection in additive manufacturing
applications & solutions
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Aerospace X-ray applicationsTurbine & compressor blades / airfoils
Typical X-ray inspection results
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Aerospace X-ray applications
Investment castings / structural castings / nozzles
Typical X-ray inspection results
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Aerospace X-ray applications
CFRP/GFRP composites & fan blades / Ceramic Matrix Comp.
Typical X-ray inspection results
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Applications & solutions
Technology IntroductionComputed Tomography
Assisted Defect RecognitionBroad AcceptanceIndustry Standards
Increasing X-ray inspection requirements driving change
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DICONDE: Standardization of digital X-ray Imaging
Existing IT Network
CR Systems DDA SystemsAutomated
DDA Systems
Rhythm Workstations (DICONDE)
FilmDigitizers
Rhythm Web Viewing(DICONDE)
Rhythm Archive (DICONDE)
Customer IS
Add any DICONDE device into your network and it will communicate with your other DICONDE systems.
DIC
ON
DE
Com
plia
nce
–AS
TM E
2339
Inline CT Systemswith ADR
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Outlook
move from classical to digital radiography on short/mid term -> DICONDE standardization + data handling & storage forward
innovative aerospace manufacturing technologies -> different kinds of defects require increased detectability
continuous challenges in terms of productivity, resolution for X-ray manufacturers -> NPI/NTI drivers
…special acknowledgement to
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Thank you very much for your kind attention !
…any questions ?
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