Surface Wave Acoustic Microscopy for Rapid NDE of Silicon Nitride Balls

Ceramic hybrid bearings have many excellent performance characteristics such as heat resistance, extended life, light weight, lower thermal expansion, electrical non-conductance, and thus become the top choice of rolling bearings for the F135 and F136 engines for the new generation Joint Striker Fighter F-35.  The main concern in using ceramic materials for bearing applications is their reliability, because small defects in the ceramic (silicon nitride) ball can cause catastrophic failure of the bearing and are particularly prejudicial when they are located close to the surface.  The existing techniques, however, can not simultaneously satisfy the requirements regarding the inspection cost, speed, resolution, and defect location (surface and subsurface).  In this proposal, Intelligent Automation Inc. (IAI) along with its consultant, Dr. Nelson N. Hsu, proposes to develop an innovative Surface Wave Acoustic Microscopy (SWAM) technique for the rapid inspection of small defects on ceramic ball bearingfs surface and subsurface. BENEFIT: We envision that the proposed SWAM technique will provide a powerful tool and have a significant impact in real-time inspection of ceramic balls for hybrid bearing manufacturers and users.  The ultimate goal of this project is to develop a rapid, low-cost, and fully automated ball bearing inspection system to improve the speed, reliability and accuracy of online inspection.  Should the proposed effort succeed, we will team up with our commercial partners such as Pratt& Whitney, Boeing, Goodrich, Honeywell, etc, to promote the use of the proposed technique and developed system