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NDT Technology Readiness
A P&WC Case Study
David M Craig
Senior Fellow & Mgr. NDT TechnologyFellow & Past National Chair – Canadian Institute for NDE (CINDE)
Export Classification: No Technical Data
2016 Airlines for America NDT Forum26-28 September, San Diego, CA
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EXPORT CLASSIFICATION
2
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14th. Annual NDT Better Way Award Winners
VIBRANTGreg Weaver
Leanne JauriquiEric Biedermann
Tom Williams
P&WCDavid CraigPeter Boyd
Gerry WhittyFrancesco Finzi-Contini
Daniel GagnonDaniel GirardJosee Caya
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Content
• Pratt & Whitney Canada (P&WC)
• NDT in the value stream
• Technology Readiness (TR)
• Case study
• Turbine blade re-design PCRT activity
• Statistical Process Control (SPC) using PCRT
• Summary
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Pratt & Whitney Canada (P&WC) - 1928
The six men who originally came to work for Canadian Pratt &Whitney Aircraft Limited in 1928. The company was founded by
James Young (3rd from right), a Montreal businessman.
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P&WC Canadian Facilities
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P&WC Employment World-Wide
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Global Customer Base
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Six Key Business Segments
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Pratt & Whitney Canada (P&WC) – 2016Three Advanced Manufacturing Intelligent Cells $275M Cdn. investment
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NDT in the Value Stream
P&WC Value Stream Video
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NDT in the Value Stream
• The 2016 NDT Better Way Award Team -
• Chief Engineers Office
• Turbine Rotating Structures
• Customer Management
• Procurement – account manager
• X-ray Computed Tomography (CT) technician and NDT
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Technology Readiness
• X-ray Computed Tomography (CT). First CT scannerinstalled at P&WC over 20 years ago.
Capability toevaluate emerging
technologieswithout a specific
need
May be dormantfor many years
before finding anapplication
Ability to rapidlyimplement a
technology to TRL8 to solve a
specific problem
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Technology Readiness (TR)
• Some other NDT technologies evaluated over theyears….
• Remote Acoustic Impact Doppler (RAID)• Resonant Ultrasonic Spectroscopy (RUS) (1994)• Alternative Current Potential Drop (ACPD)• Sonic IR / Thermosonics / Vibrothermography• …..
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Technology Readiness (TR)
• Resonant Ultrasonic Spectroscopy (RUS) / ProcessCompensated Resonance Testing (PCRT) a 22 yearjourney….
EASAMeetingRome
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Case Study…initial mandate…
• Systemic issue with turbine blades relatedto various casting flaws
• Eliminate unique casting flaws that are notdetected by current inspection methodsthat result in quality escapes. Theseinclude, but are not limited to, cold shots,non-metallic inclusions, non-homogeneous material, under min. wallthickness, aluminum rich layer, etc.
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Typical casting anomalies
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TR link…
• Connection made back to the early 90’s RUS work – fullpart inspection, quick, sensitive to material flaws, etc.
• Vibrant contacted and technology had matured significantlyto Process Compensated Resonance Testing (PCRT)
• Allows for normal process variation while still detecting targetdefects
• Population characterization identifies outlier parts with singulardefect conditions
• Quantifiable output monitors part flow over time to show process orcomponent drift outside of the norm
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PCRT system
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Typical resonance spectra
The PCRT System applies pattern recognition to the entireresonance spectra of the component being tested
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PCRT
Analysis Tools
Z-Score
Method
Outlier Screening /Process Monitoring
VIPR
Method
(Targeted Defect)
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Casting pilot study
• 2400+ castingsinspected
• VIPR sort hadrelatively goodcorrelation with x-rayinspection data
• < 10 second
inspection per casting
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Quality issue attributed to shrinkage porosity
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X-ray film review
• Review of production x-ray film(where available) of the castingrevealed two issues –
• Shrinkage porosity in the vicinity ofthe blade pocket not detectedduring x-ray inspection
• Shrinkage porosity indication onthe x-ray film but missed by theinspector
• 40% / 60% ratio
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Shrinkage porosity
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Shrinkage porosity
• Equiaxed casting
• Shrinkage porosity difficult to detect and interpret usingconventional film (orientation, grain diffraction (mottling),etc.)
• Digital Radiography (DR) and X-ray ComputedTomography (CT) utilized to select blades for VIPRtraining
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Shrinkage porosity
• DR Image
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Shrinkage porosity
• DR Image
• Classified as “heavy” shrinkage porosity
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Shrinkage porosity
• CT slice
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PCRT inspection booth
• P&WC PCRTproductioninspection set-up
• Inspectionservice P&WC /Vibrant
• >140,000 bladesinspected toVIPR
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• VIPR progression (6 off)
VIPR progression (6 off)
VIPR Rev1-4
• Train to small number of confirmed defects• Use conservative limits with lower yield to immediately
quarantine suspect blades• Yield 70-90%
VIPR Rev5-6
• Further examine severity of defects relative to population• Align targets with engine field performance data• Re-test quarantined components• Yield 95+%• 7000 blades scrapped
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Event rate reduction• Latest field data attributed to shrinkage porosity – 1 false negative
(Rev 1 VIPR). Two post PCRT lead-the-fleet engines at over 6000hrs
PRE – PCRT Blades
PCRT implementedOctober 2012
Fals
en
eg
ati
ve
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Casting re-design
• In conjunction with the inspection activity, Engineeringinitiated a re-design of the casting
• Result: Improved creep life in the airfoil
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Statistical Process Control (SPC) using PCRT
• Since re-design: Automated production processmonitoring of castings
• Z-score
• Incorporates a vision system for reading of the castingS/N (reduced human factor)
• Approx. 51,000 castings tested to-date
• Reject rate < 1.0%
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Statistical Process Control (SPC) using PCRT
Vibrant Robotic System Video
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Statistical Process Control (SPC) using PCRT
B
o
u
n
d
a
r
y
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PCRT – emerging trend related to dimensionalvariations in blade castings• Other limited studies are trending towards a dimensional
variation in the blade profile of PCRT Outliers
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PCRT – emerging trend related to dimensionalvariations in blade castings
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PCRT – the dilemma, quandary, predicament orimpasse….
• In some cases, cause of resonance Outlier signalcannot be conclusively identified
• Relate this resonance difference to blade performancein an engine
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The TR Advantage
TRL 1-6
• Initial evaluation of technology in development mode• 3222 casting study - showed sensitivity to X-ray indications
TRL 6
• Testing on real parts• Additional inspection gate quickly established to protect the field• VIPR 1
TRL 7
• First engine to test• VIPR 6 established to better align with performance data
TRL 8
• Production implementation• Z-score SPC on re-designed casting
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Summary
• Need to be pro-active and evaluate emerging NDT technologies in acontrolled manner away from the extreme pressure of a production orfield inspection need – Technology Readiness
• Using Technology Readiness history P&WC was able to rapidlyimplement a PCRT inspection process that met the expectation of thevarious aviation regulatory bodies thus allowing the fleet to continueflying
• NDT is no longer just an inspect tool. It contributes significantly to thevalue stream and life cycle management of gas turbine aircraftengines on a daily basis
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A promise founded upon excellence inquality, ethics and rigour every day!