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NDI Considerations For Implementing Deep Residual Stress Treatments

This document discusses considerations for implementing deep residual stress treatments from a non-destructive inspection (NDI) perspective. It outlines current knowledge and gaps regarding how residual stress impacts NDI methods like ultrasonic testing and eddy current. Deep residual stresses can create ultrasonic "dead zones" near features like cold-worked holes that reduce NDI capability. The document calls for further research to quantify these effects and define correction factors. It also notes that qualification of residual stress treatments must account for their impact on detecting residual flaws or cracks. Finally, it recommends updating guidance and policy documents to summarize lessons learned and define limitations for NDI when residual stresses are present.

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64 views

NDI Considerations For Implementing Deep Residual Stress Treatments

This document discusses considerations for implementing deep residual stress treatments from a non-destructive inspection (NDI) perspective. It outlines current knowledge and gaps regarding how residual stress impacts NDI methods like ultrasonic testing and eddy current. Deep residual stresses can create ultrasonic "dead zones" near features like cold-worked holes that reduce NDI capability. The document calls for further research to quantify these effects and define correction factors. It also notes that qualification of residual stress treatments must account for their impact on detecting residual flaws or cracks. Finally, it recommends updating guidance and policy documents to summarize lessons learned and define limitations for NDI when residual stresses are present.

Uploaded by

puhumight
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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NDI Considerations

for Implementing Deep


Residual Stress Treatments

Engineering Residual Stress


Implementation – Panel
ASIP Conference 2017

John Brausch
AFRL/RXSA, Systems Support Division
Materials and Manufacturing Directorate
Integrity  Service  Excellence Air Force Research Laboratory
Wright-Patterson AFB, OH 45433
Distribution A: Approved for Public Release. Distribution unlimited. Case# 88ABW-2017-5724
Overview

• Current Knowledge
• Gaps
• Qualification: Design vs Sustainment
• Guidance and Policy

Distribution A: Approved for Public Release. Distribution unlimited. Case# 88ABW-2017-5724 2


Applied Compressive Stress
Shear-Wave Ultrasonics

Ultrasonic response from fatigue cracks under applied


compressive stress.

7075-T6 Aluminum

Henry, T. “Correlating Ultrasonic Responses of Fatigue Cracks


Propagated Under Different Load Spectra.”

Significant Impact
~6dB (50%) signal reduction per 4 ksi applied compressive stress.
Laser Shock Peening
Eddy Current, Ultrasonics, Fluorescent Penetrant

Eddy Current Ultrasonics Fluorescent Penetrant

Eddy Current Response versus Measured Length


US-3515/3516 Probe
300 2.5
ECI Response - LSP
y = 106.61ln(x) + 393.33
ECI Response - No LSP 2.3

250 Log. (Gain Difference)


Eddy Current Signal Amplitude (%FSH)

2.1

1.9
200
Gain Difference (ΔdB)

y = 95.4ln(x) + 350.33
1.7

150 1.5

1.3

100
1.1

0.9
50
0.7

0 0.5
0.000 0.050 0.100 0.150 0.200 0.250 0.300 0.350
Measured Surface Length (inch)

Minimal Impact Significant Impact Significant Impact

Distribution A: Approved for Public Release. Distribution unlimited. Case# 88ABW-2017-5724


4
Hole Cold Working
Eddy Current, Ultrasonics,

Rotary Hole Eddy Current Surface Eddy Current Ultrasonics

Crack
tunneling

Forsythe, D., Mills, T. “Results of Study of Applied Stress and CX


Process on Detectability of Fatigue Cracks”

Minimal Impact Significant Impact Significant Impact

Distribution A: Approved for Public Release. Distribution unlimited. Case# 88ABW-2017-5724


5
Ultrasonic “Dead-Zone” in Cx Holes

 Dead zone proportional to hole diameter but scatter suggests other influencing factors.
 Use upper bound of UT dead zone estimates to correct UT POD estimates for Cx holes.
 Ultrasonic inspections must be designed to interrogate beyond the tangency of the hole.

Ultrasonic “dead zone” proportional to hole diameter.


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Gaps

• Quantify Ultrasonic “Dead Zone” at Cx Holes


- Quantify UT “Dead Zone” for a range of Cx applied expansion ranges
- Investigate causes of “Dead Zone” variability
- Define UT POD correction factors for Cx holes
- Define optimum UT system design for Cx holes
• Fastener Installation on UT Detectability
- Taper-Lok fasteners
- Interference fit fasteners
- Interference fit fasteners installed at Cx holes
• Other ERS Surface Treatments and Materials
- Shot peening, low plasticity burnishing – on aluminum and titanium (UT and
FPI focused)
- Laser Shock Peening (LSP) on titanium alloys

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Qualification
Design vs Sustainment

Implementation in Design
• ERS impact on NDI capability must be quantified.
• Qualification must include application of ERS treatment over
remnant rogue flaw defined by production NDI capability.
Implementation in Sustainment
• ERS impact on NDI capability must be quantified.
• Qualification must include application of ERS treatment over
remnant fatigue crack with size based on pre-ERS NDI capability.

NDI Data Capture/Retention Requirements


Must document “defect-free” condition before ERS application

Implementing deep residual stress treatments limits NDI


options and capability for sustainment inspections.
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Guidance and Policy

Guidance
• NDI Best Practices Guide – update to include summary of
overall impacts and lessons learned
• T.O. 33B-1-1, NDI Methods, Basic Theory
o Summary of overall impacts
Policy
• EN-SB-008-012 - In-Service Inspection Flaw Assumptions for
Metallic Structures
o Define capability limitations and correction factors
o Publish standard correction factors for POD estimates and
POD models.
• T.O. 33B-1-2, NDI Gen. Procedures and Process Controls
o Define procedural restrictions
• New SB for ERSI
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