Hybrid NDE Methods for Linear Friction Weld Characterization in IBRs

Linear friction welding is an attractive process for performing full blade repair in Integrally Bladed Rotors (IBRs), as it produces good material properties and small heat-affected zones. An effective Nondestructive Evaluation (NDE) method is required for Linear Friction Welds (LFWs) in IBRs that can provide full volumetric inspection. At the same time, the inspection must be performed within the limited space between blades and accommodate the varying curvature of the air foil surfaces. JENTEK’s patented Meandering Winding Magnetometer (MWM) and MWM-Arrays have demonstrated superior performance for detecting cracks in difficult-to-inspect areas of aircraft engine components. Our automated engine disk slot and blade dovetail inspection systems have been awarded the FAA-ATA Better Way Award and are standard practice at U.S. military depots. Under an on-going SBIR program, MWM-Arrays are currently being adapted for scanning air foils, fillets and leading/trailing edges of IBRs. This proposed program will address the need for full volumetric examination of LFWs by combining high frequency MWM scanning with either deep penetration, low frequency eddy current or with UT scanning. We will also evaluate capability to characterize the microstructure of the material in the thermomechanically affected zone adjacent to the LFW.