Presentazione completa 2012

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MONITORING CAPABILITY OF THE TAM PANELL FOR SYSTEM PERFORMANCE VERIFICATION

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• ASTM E1417-11ε1

• PRIME SPECIFICATION THAT FORESEEN THE SYSTEM PERFORMANCE

VERIFICATION THROUGH TAM PANEL PSM-5, AS:

• GE Aviation:P3TF2/P3TF47 – Rolls Royce: RPS702/EIS1169 –

Pratt&Whitney:FPM MASTER - SNECMA/SAFRAN: DMC0010 – MTU: MTV

1030 – Honeywell: 52309 - Aviogroup: 9300F – Agusta

Westland:AWPS006X

REFERENCE SPECIFICATION

Premises

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• In the “Top 5 Checklist Findings for 2011 “- AC7114/1 the first 4 places include topics relevant to the System Performance Verification or to the control of the TAM Panel

• TAMs, became “reference standard”, especially in the aerospace, but nevertheless few test have been performed to document their capability to realize actually what the specification expect by them.

• The purpose has always been to establish the "BASELINE" conditions of the know defect standard casting - that is the initial condition of the Performance of the Penetrant System , to be compared daily in monitoring the System.

RELEVANT ISSUES

Premises

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(Penetrant System Monitoring – 5 indications)

“STARBUST”TAM (Testing And Monitoring)

A B C D E

TAM PSM-5

Manufactured on the basis of the original P&W drawing

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Identification of the Starbust A B C D E

Dimensional range (mm.) 0.38 ÷ 0.79 1.17 ÷ 1.57 1.91 ÷ 2.36 3.18 ÷ 4.34 4.57 ÷ 6.35

Drawing & Dimensions from Pratt&Whitney 146040

TAM PSM-5

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TYPE OF TAM PANEL

• TAM 146040-1: It shows chrome-plated surfaces and mirror polished in the area where the artificial defects are placed.

• TAM 146040-2: It shows everywhere sandblasted surfaces

TAM PSM-5

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Sensitivity level of the Penetrant

Minimum number of surface indications

Classificationof the defectsto be found

2 3 C,D,E3 4 B,C,D,E4 5 A,B,C,D,E

BASELINE PROCESS• Minimum number of TAM panel defects visible

during PT

TAM PSM-5

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BASELINE PROCESSTAM PSM-5

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S/N 28220

970P25E

S/N 33995

S/N 31334

RC 77

S/N 31335

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• Document the "real" capability of these tools in 'carrying out the daily System Performance Verification for which they are employed.

• Determine the effectiveness of these known defect standards by checking if they are able to discriminate deviations exceeding the limits of the specification, even very slight, connected to the control of the penetrant process.

TARGET of the TEST

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a) Chemical contamination of the penetrant and of the emulsifier

Performed tests

b) Temperature variations of the penetrant

c)Variation of penetrant and developer dwell time

Check influences on the process control through:

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POLLUTANTS

TEST PARAMETERS

Pressure Time Temperature

Performed Tests

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Sherwin Hydrofilic Emulsifier ER83A

Ardrox WW Penetrant 970P25E

Type 1 Method A Level 3

Sherwin PE PenetrantRC 77

Type 1 Method D Level 4

Sodium Hydroxyde (2-5-7-

10 % v/v)

Nitric Acid (2-5-7-10 % v/v)

Water(5-10-15-20 % v/v)

Ardrox WW Penetrant HM430


Turco 4215 NC-LT

(30 % v/v)

Pollutants

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Test identification

S/N 28220

Detailsof test

parameters

S/N 33995

Green square highlights a substantial invariance of the performance of the

TAM respect to the BASELINE

S/N 28220

Detailsof test

parameters

S/N 33995

Red square highlights a substantial variance of the performance of the TAM respect to the BASELINE

Name Product – Test Parameters

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Pollutants

S/N 28220

5%

S/N 33995

S/N 28220

10%

S/N 33995

ARDROX 970P25 – H2O (5-10 %v/v)

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Pollutants

S/N 28220

15%

S/N 33995

S/N 28220

20%

S/N 33995

ARDROX 970P25 – H2O (15-20 %v/v)

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Pollutants

S/N 31334

5%

S/N 31335

S/N 31334

10%

S/N 31335

SHERWIN RC77 – H2O (5-10 %v/v)

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Pollutants

S/N 31334

15%

S/N 31335

S/N 31334

20%

S/N 31335

SHERWIN RC77 – H2O (15-20 %v/v)

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S/N 28220

2%

S/N 33995

S/N 28220

5%

S/N 33995

ARDROX 970P25 – HNO3 (2-5 %v/v)

Pollutants

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Pollutants

S/N 28220

7%

S/N 33995

S/N 28220

10%

S/N 33995

ARDROX 970P25 – HNO3 (7-10 %v/v)

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Pollutants

S/N 31334

2%

S/N 31335

S/N 31334

5%

S/N 31335

SHERWIN RC77 – HNO3 (2-5 %v/v)

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Pollutants

S/N 31334

2%

S/N 31335

S/N 31334

5%

S/N 31335

SHERWIN RC77 – NaOH (2-5 %v/v)

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Pollutants

S/N 31334

7%

S/N 31335

S/N 31334

10%

S/N 31335

SHERWIN RC77 – NaOH (7-10 %v/v)

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Pollutants

S/N 28220

2%

S/N 33995

S/N 28220

5%

S/N 33995

ARDROX 970P25 – NaOH (2-5 %v/v)

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Pollutants

S/N 28220

7%

S/N 33995

S/N 28220

10%

S/N 33995

ARDROX 970P25 – NaOH (7-10 %v/v)

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Pollutants

S/N 31334

2%

S/N 31335

S/N 31334

5%

S/N 31335

SHERWIN ER83A – NaOH (2-5 %v/v)

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Pollutants

S/N 31334

7%

S/N 31335

S/N 31334

10%

S/N 31335

SHERWIN ER83A – NaOH (7-10 %v/v)

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Pollutants

S/N 31334

10%S/N

31335

SHERWIN ER83A – HNO3 ( 10%v/v)

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Pollutants

S/N 31334

20%S/N

31335

SHERWIN ER83A – H2O ( 20%v/v)

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SHERWIN HM430 – TURCO 4215 NC-LT (30 %v/v)

Pollutants

S/N 28971

30%S/N

28218

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Water pressure


Type 1 Method A Lev 3


Type 1 Method D Lev 4

Washing pressure

50-300 kPa

ARDROX 970P25 50-300 kPa

TEST PARAMETERS :

WATER PRESSURE

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S/N 31334

50 kPa

S/N 31335

S/N 31334

300kPa

S/N 31335

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S/N 31334

50 kPa

S/N 31335

S/N 31334

300 kPa

S/N 31335

SHERWIN RC77 50-300 kPa

TEST PARAMETERS :

WATER PRESSURE

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Time



Dwell time with liquid penetrant

Developping time(4-10-30-60 min.)

Immersion

(min.)

Draining

(min.)

0 0

2 2

5 5

1 15

60 60

34S/N 28971 S/N 28217 S/N 28218

SHERWIN HM430Immersion 1 sec. – Draining 1 sec.

TEST PARAMETERS:

PENETRANT DWELL TIME

35S/N 28971 S/N 28217 S/N 28218

SHERWIN HM430Immersion 2 min. – Draining 2 min.

TEST PARAMETERS:


36S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


37S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


38S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


39S/N 28971 S/N 28217 S/N 28218

SHERWIN HM430 – 4 min.

TEST PARAMETERS:


40S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


41S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


42S/N 28971 S/N 28217 S/N 28218


TEST PARAMETERS:


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Temperature



PenetrantTemperature

(5°-50°-80 °C)





Drying Temperature(100-120 °C)

Washing Temperature (5°-50°-80 °C)

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SHERWIN HM430 5 °C

TEST PARAMETERS:PENETRANT

TEMPERATURE

S/N 28971

5°CS/N

28218

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SHERWIN HM430 50 °C

S/N 28971

50°CS/N

28218


TEMPERATURE

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SHERWIN HM430 80 °C

S/N 28971

80°CS/N

28218


TEMPERATURE

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S/N 28220

5 °CS/N

33995

S/N 31334

S/N 31335

ARDROX 970P25 - SHERWIN RC77 5 °C

TEST PARAMETER:

WASHING REMPERATURE

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S/N 28220

50 °CS/N

33995

S/N 31334

S/N 31335


TEST PARAMETER:

WASHING REMPERATURE

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S/N 28220

80 °CS/N

33995

S/N 31334

S/N 31335


TEST PARAMETER:

WASHING REMPERATURE

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S/N 28220

100°C

S/N 33995

S/N 28220

120°C

S/N 33995

ARDROX 970P25 100-120 °C

TEST PARAMETERS:

DRYING TEMPERATURE

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S/N 31334

100 °C

S/N 31335

S/N 31334

120 °C

S/N 31335

SHERWIN RC77 100-120 °C

TEST PARAMETERS:

DRYING TEMPERATURE

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Temperature &

Time

Drying Temperature(25°-80 °C)





Drying Time(30-60 min.)

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S/N 28220

25 °C

S/N 33995

S/N 28220

80 °C

S/N 33995

ARDROX 970P25 25°- 80 °C 15 min.

TEST PARAMETERS:

TEMPERATURE / TIME DI OF DRYING

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S/N 31334

25 °C

S/N 31335

S/N 31334

80 °C

S/N 31335

SHERWIN RC77 25°- 80 °C 15 min.

TEST PARAMETERS:


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S/N 31334

30 min.

S/N 31335

S/N 31334

60 min.

S/N 31335

SHERWIN RC77 65 °C 30-60 min.

TEST PARAMETERS:


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S/N 28220

30 min.

S/N 33995

S/N 28220

60 min.

S/N 33995

ARDROX 970P25 65 °C 30-60 min.

TEST PARAMETERS:


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Conclusions (1)

The addition of sodium hydroxide does not show significant effects about the process monitoring at all tested concentrations

The presence of water, causes a progressive attenuation of the intensity of the indications and a degradation of their size - At levels of 15 -20% only parts of the two discontinuities of greater dimensions (D – E) are still visible

Alkaline degreasers in aqueous solution such as the TURCO 4215 NC-LT not seem to have impact on the effectiveness of the Penetrant System

Pollutants in the emulsifier, used for high sensitivity penetrant cause no tangible effects - only nitric acid causes valuable changes!

The presence of nitric acid , progressively eliminates the brightness of the penetrant, which remains almost unchanged up to a concentration of 2% (v / v)

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Conclusions (2)

Increasing the temperature in the oven drying occurs a progressive deterioration of the sharpness of the indications accompanied by the deposition of fluorescent pigment from the temperature of 100 ° C. The dwell time of greatest impact on water washable reducing penetrant brightness and sharpness of starbusts

The obtained results appear to be insensitive to changes in penetrant dwell time (immersion and draining), ranging from a few seconds up to one hour and to variations in the application temperature from 5 ° C to 80 ° C!

Increasing the pressure of the water washing a small attenuation of the brightness of the individual indications has been observed, but no dramatic evidence appear even up to 300 kPa

The variation of washing temperatures (operation, typically performed in the range 10 ° to 38 ° C) is not detected during System Performance effectiveness. After a washing at 80 ° C It is still valuable the starbust A

Conclusions (3)

WHAT IS APPEARING FROM THE OBTAINED RESULTS:

1) The TAM PANEL 146040 showed some limits relevant to the possible drift of the penetrant process.

2) Therefore, there is the possibility to have working conditions do not conform to the applicable requirements ….

BUT……………. 3) What can happen instead on the actual defects in the inspected

components? 4) And 'the magic halo attributed to this instrument which is delegated

to the effective Performance Effectiveness Verification of the system is justified?

The evidence of the monitoring do not seem to be affected by the percentage of dwell time - immersion respect to that of drainage

The tests reveal no variations due to different development time used, at least in the range tested.

Conclusions (4)

After all these consideration about the TAM146040 effectiveness,what do we have to consider about the its supply condition?

For a good daily practice, it is mandatory the initial fulfillment of 146040 drawing requirements , about the 5 starbusts size ?

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Special Thanks / Credits

Thanks to the article of George Hopman published on “Material Evaluation” - February 2009 …It has given us an opportunity to deepening the concept concerning an subject that raised so many issues during the audit

A special thanks to a couple of colleagues:

A.Martignetti and G. Petronella – Alenia Aermacchi who have shared and contributed to the development of these subjects.

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Question time

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Presentazione completa 2012

Engineering

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