Ultrasonic Detection for Fiber Broken in Aero-Engine Integral Bladed Ring

doi:10.11900/0412.1961.2019.00441

Acta Metall Sin

2020, Vol. 56

Issue (8): 1175-1184 DOI: 10.11900/0412.1961.2019.00441

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Ultrasonic Detection for Fiber Broken in Aero-Engine Integral Bladed Ring

WU Yupeng¹^,², ZHANG Bo¹(

), LI Jingming¹, ZHANG Shuangnan¹, WU Ying¹, WANG Yumin¹, CAI Guixi¹

1 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China

Cite this article:

WU Yupeng, ZHANG Bo, LI Jingming, ZHANG Shuangnan, WU Ying, WANG Yumin, CAI Guixi. Ultrasonic Detection for Fiber Broken in Aero-Engine Integral Bladed Ring. Acta Metall Sin, 2020, 56(8): 1175-1184.

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Abstract

The fiber fracture is a very dangerous defect in the aeroengine integral bladed rings which is manufactured by continuous SiC fibers-reinforced titanium alloy matrix composite (Ti-MMC). Currently the lack of an effective method for inspecting the fiber fracture seriously influences the quality control of the aeroengine integral bladed rings, therefore solving the problem of non-destructive testing for deep buried radial micro-cracks is an insurmountable barrier for the application of Ti-MMC integral bladed rings in aviation. In this work, based on the theory of ultrasonic head-waves, the refraction longitudinal waves with the proper angle generated by the creeping wave probe are propagated on the interface, which means the creeping wave with high energy is generated. The finite element simulation model of the creeping wave is established for inspecting the defect of SiC fibers breakage in Ti-MMC aero-engine bling structure. Based on the results of the finite element simulation, significant defect signal waves are generated in the water layer above the defect. After that, not only the ultrasonic propagation characteristics at the interface of multilayer media but also the diffraction phenomenon of the creeping wave when they encounter the broken wire defect are analyzed. And the detection signal amplitude is not only affected by the incident angle of the creeping probe but also is related to the thickness of titanium alloy. In order to receive the diffracted waves with high sensitivity, the assembled probe, which is composed by a creeping wave exciter (5 MHz, 20°) and an immersion focusing sensor (5 MHz, diameter 6 mm), is specially designed and manufactured according to the results of the finite element simulation. In addition, the artificial sample with the broken fiber is prepared and then tested by the ultrasonic C-scan testing system with the assembled probe. The results show that the three-layer broken wire defects (the crack height is about 0.42 mm) with different depths in the artificial sample can be detected successfully. The C-scan results can match the defect positions of the artificial sample which means this detection method is valid. This method is simple, economical and fast, and is expected to solve the problem of nondestructive testing for broken wire in the deep embedded fiber ring in the Ti-MMC aero-engine bling structure.

Key words: integral bladed ring continuous SiC fiber composite ultrasonic testing creeping wave

Received: 23 December 2019

ZTFLH:

O426.9

Fund: National Natural Science Foundation of China(51605468);Technology Innovation Project of Function Development of Instrument and Equipment, Chinese Academy of Sciences(Y8M1734171);Natural Science Foundation of Liaoning Province(2019-MS-334)

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	Yupeng WU
	Bo ZHANG
	Jingming LI
	Shuangnan ZHANG
	Ying WU
	Yumin WANG
	Guixi CAI

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00441 OR https://www.ams.org.cn/EN/Y2020/V56/I8/1175

Fig.1 The manufacturing process of the integral bladed ring (Ti-MMC—titanium alloy matrix composite)
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Fig.2 Schematics of defect morphology of the integral bladed ring manufactured by SiC fiber-reinforced Ti-MMC

Fig.3 A head wave system formed by the incidence of a special longitudinal wave P₁ (λ, μ—elastic constants; ρ—density; S—shear wave, P—longitudinal wave; C_L—P-wave velocity, C_S—shear wave velocity; 1—mediume Ⅰ, 2—mediume Ⅱ; point S—hypocenter; i₁—first critical angle; point C(r, z)—arbitrary position on the wavefront in the first medium, r—the horizontal distance from point C to the source; z—vertical distance from point C to the interface)^[23]

Fig.4 Schematic of time of flight diffraction (TOFD) detection principle

Fig.5 The detection method by creeping wave probe and water immersion focusing probe

Fig.6 The simulation model of head wave system in the simple structure

Fig.7 The signal for exciting

Fig.8 The distributions of sound field at different time (t) (P_s—scattered longitudinal wave at the tip of piezoelectric wafer; 1—water medium; 2—Ti alloy medium; P₁P₂S_2d—shear wave derived from the down-interface of Ti alloy board, where d—down）(a) t=1.25 μs (b) t=1.65 μs (c) t=2.75 μs
Color online

Fig.9 The simulation model of the ultrasonic detection for fiber fracture in the integral bladed rings

Fig.10 The distribution of sound field at different time (C_L-Ti—sound velocity of ultrasonic longitudinal waves in titanium alloy; C_L-SiC—velocity of ultrasonic longitudinal waves in SiC; 1—water medium; 2—Ti alloy medium; 3—SiC medium)
Color online
(a) t=2.2 μs (b) t=3.45 μs (c) simplified schematic of two head wave systems (d) t=4.9 μs

Fig.11 The sound fields of the defective diffraction wave incidencing water(a) total sound field(b) partial enlarged sound field
Color online

Fig.12 The comparison of ultrasonic signals with and without defects

Fig.13 The detection signal amplitude affected by the probe angle

Fig.14 The detection signal amplitude affected by the thickness of titanium alloy

Fig.15 Ti-MMC specimen with the defect of fiber fracture (unit: mm) (a) front view (b) left view
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Fig.16 The assembled probe (PZT—Pb(ZrTiO₃) piezoelectric ceramics; unit: mm)

Fig.17 The C-scan test results of the artificial sample with the broken fiber
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Fig.18 The A-scan signals of the artificial sample on typical positions corresponding points A~D in Fig.17
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(a) point A without fiber fracture (b) point D with fiber fracture in the lower layer
(c) point C with fiber fracture in the middle layer (d) point B with fiber fracture in the upper layer

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