Non-Destructive Inspection for Repaired Integrally Bladed Disk Airfoils

ABSTRACT: The US Air Force seeks an innovative nondestructive evaluation (NDE) technique to assess the integrity and microstructure state of integrally bladed disk (IBD) airfoils after repairs. The IBD repair process typically involves machining away the damage portion, refilling materials using either additive type processing methods or welding a patch on it, restoring material microstructure through post heat treatment, and restore the original blade shape via machining. One big concern to the IBD repairs in the mechanical property knock-down. Therefore, a NDE technology capable of assessing the repair material microstructure and mechanical properties, as well as detecting internal and surface flaws is highly desirable. In this proposal, X-wave Innovations, Inc. (XII) outlines an innovative Quantitative Acoustic Microscopy (called QAM) technology. Phase I program is to develop a prototype system and demonstrate the feasibility of the proposed QAM technique. For the Phase II program, XII will focus on refining the prototype system design and development with improved hardware and software.For the Phase III program, XII will focus on commercializing the developed QAM technology.; BENEFIT: The proposed QAM system has many market applications in different industries such as the air and space vehicles, power generators, and advanced new material research. The total market will increase in the future because the characterization of material properties and detection of defects is essential for many important material systems. The proposed research provides a great support for improvement of the integrity and safety of repaired IBD airfoils. Such a system will benefit the enhancement of the lifetime and durability and the reduction of failure risk of the engine.