The field of the invention relates generally to non-destructive testing of components, and more particularly to methods and apparatus for non-destructive testing components using an omni-directional eddy current (EC) probe.
EC inspection devices may be used to detect abnormal indications in a component under test such as, but not limited to, a gas turbine engine component. For example, known EC inspection devices may be used to detect cracks, dings, raised material, and/or other imperfections on a surface and/or within the component. EC inspection devices may also be used to evaluate material properties of the component including the conductivity, density, and/or degrees of heat treatment that the component has encountered.
EC images are typically generated by scanning a part surface with a single element EC coil. An imperfection on, or within, the part surface is detected by the EC element when it traverses the complete extent of the imperfection. At least some known eddy current array probe (ECAP) imaging, however, consists of an array of EC elements that scan the surface of a part in one direction. Using an array of EC elements reduces inspection time and increases inspection speed when compared to a single EC element scan. However, ECAP images require processing prior to flaw detection. Specifically, processing is necessary because an imperfection detected during a scan using ECAP may be seen only in partial by several EC element coils, rather than being seen completely by only one EC element coil as occurs with single-coil EC imaging.
In addition, the use of known EC probes may be limited by the fact that a prior knowledge of crack orientation is required. Because of the directionality of differential eddy current probes, if more than one flaw orientation is anticipated, the test specimen may require repeated scanning in different orientations to detect the flaws. Such repeated scanning is time consuming and may be inefficient.
In one embodiment, a method for testing a component using an eddy current array probe is described. The method includes calibrating the eddy current array probe, collecting data from the eddy current array probe for analysis, and processing the collected data to at least one of compensate for response variations due to a detected orientation of a detected imperfection and to facilitate minimizing noise.
In another embodiment, an eddy current flaw detection system is described. The flaw detection system includes an eddy current array probe and a processing device coupled to the eddy current array probe. The processing device is configured to collect data from the eddy current array probe and compensate collected data for varying orientations of detected imperfections.
In another embodiment, an eddy current array probe calibration device is described. The calibration device includes a plurality of test notches oriented in a plurality of rows and columns, wherein adjacent rows are separated by a predetermined distance, and wherein adjacent columns are separated by a predetermined distance. The calibration device also includes a voltage measuring device configured to measure a sensed voltage detected by the eddy current array probe at each of the plurality of notches.
In another embodiment, a method of calibrating an eddy current array probe is described. The method includes positioning a plurality of notches in a predetermined manner on a test block, measuring a voltage sensed by the eddy current array probe for each of said plurality of notches, and setting a gain of the eddy current array probe based on the measured voltage.
In one embodiment, an automated defect recognition (ADR) process for a Wide Area Standard Probe (WASP) is described herein. The WASP is a type of eddy current inspection probe that facilitates an efficient and productive inspection process through the use of a multi-element scan. A unique advantage of the WASP is its ability to detect flaws in substantially any orientation, such that a limited amount of data is obtained in comparison to other known eddy current probes. However, the benefits gained through the acquisition of a limited amount of data, may be offset by the reliability of inspections completed with such probes.
In an exemplary embodiment, the ADR process automates the entire data processing procedure. The ADR method also facilitates reliable flaw recognition and characterization, while minimizing false defect identification. In the exemplary embodiment, signal processing algorithms are used to identify potential defect signals from the WASP inspection data and to estimate the size and orientation of the defects. The algorithms establish criteria used to estimate the orientation of the defect and to apply appropriate corrections in order to facilitate maximizing the response from the defect. In addition, the algorithms may function without the use of reference images, look-up-tables, or any other a priori information.
Although the methods and apparatus herein are described with respect to posts 56 and dovetail slots 58, it should be appreciated that the methods and apparatus can be applied to a wide variety of components. For example, the present invention may be used with component 52 of any operable shape, size, and/or configuration. Examples of such components may include, but are not limited to only including, components of gas turbine engines such as seals, flanges, turbine blades, turbine vanes, and/or flanges. The component may be fabricated of any base material such as, but not limited to, nickel-base alloys, cobalt-base alloys, titanium-base alloys, iron-base alloys, and/or aluminum-base alloys. More specifically, although the methods and apparatus herein are described with respect to aircraft engine components, it should be appreciated that the methods and apparatus can be applied to, or used to inspect, a wide variety of components used within a steam turbine, a nuclear power plant, an automotive engine, or any other mechanical components.
In the exemplary embodiment, detection system 50 includes a probe assembly 60 and a data acquisition/control system 62. Probe assembly 60 includes an eddy current (EC) coil/probe 70 and a probe manipulator 72 that is coupled to probe 70. Eddy current probe 70 and probe manipulator 72 are each electrically coupled to data acquisition/control system 62 such that control/data information can be transmitted to/from EC probe 70 and/or probe manipulator 72 and/or data acquisition/control system 62. In an alternative embodiment, system 50 also includes a turntable (not shown) that selectively rotates component 52 during the inspection procedure.
Data acquisition/control system 62 includes a computer interface 76, a computer 78, such as a personal computer with a memory 80, and a monitor 82. Computer 78 executes instructions stored in firmware (not shown), and is programmed to perform functions described herein. As used herein, the term “computer” is not limited to just those integrated circuits referred to in the art as computers, but rather broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein.
Memory 80 is intended to represent one or more volatile and/or nonvolatile storage facilities that shall be familiar to those skilled in the art. Examples of such storage facilities often used with computer 78 include, but are not limited to, solid-state memory (e.g., random access memory (RAM), read-only memory (ROM), and flash memory), magnetic storage devices (e.g., floppy disks and hard disks), and/or optical storage devices (e.g., CD-ROM, CD-RW, and DVD). Memory 80 may be internal to, or external from, computer 78. Data acquisition/control system 62 also includes a recording device 84 such as, but not limited to, a strip chart recorder, a C-scan, and/or an electronic recorder that is electrically coupled to either computer 78 and/or eddy current probe 70.
In use, a component 52, such as disk 54, is mounted on a fixture (not shown) that secures the component 52 in place during inspection. Eddy current probe 70 is selectively positioned within dovetail slots 58 to facilitate enabling substantially all of the interior of dovetail slots 58 to be scanned during inspection. In the exemplary embodiment, probe manipulator 72 is a six-axis manipulator. EC probe 70 generates electrical signals in response to the eddy currents induced within the surface of dovetail slots 58 during scanning of dovetail slots 58 by probe 70. Electrical signals generated by EC probe 70 are received by data acquisition/control system 62 via a data communications link 86 and are stored in memory 80 and/or recorder 84. Computer 78 is also coupled to probe manipulator 72 by a communications link 88 to facilitate controlling the scanning of disk 54. A keyboard (not shown) is electrically coupled to computer 78 to facilitate operator control of the inspection of disk 54. In the exemplary embodiment, a printer (not shown) may be provided to generate hard copies of the images generated by computer 78.
In the exemplary embodiment, system 50 may be used to perform any kind of eddy current inspection, such as conventional inspection, single-coil inspection, or array probe inspection. System 50 automatically scans the surface of component 52 and stores the acquired data in the form of images. The defect recognition algorithms will then be employed by computer 78 to identify and characterize any flaw (if present) on the surface of component 52.
When an eddy current (EC) test is performed, a magnetic field is generated by a drive coil. Such generation may include, but is not limited to only, supplying an alternating current to a drive coil. The drive coil is positioned adjacent to a surface of a component to be tested. When the drive coil is positioned, the drive coil is oriented substantially parallel to the surface being tested. Such an orientation of the drive coil causes the magnetic field generated by the drive coil to be oriented substantially normal to the surface being tested.
A sensor is coupled to the drive coil to receive secondary fields. Secondary fields of interest are received at the sensor after the magnetic fields generated by the drive coil are reflected from a surface flaw on, or in, the surface being tested. The sensor is configured to convert the reflected secondary field into an electric signal that may be viewed and/or recorded.
Omni-directional EC probe 130 also includes at least one drive coil 138 that generates a probing field for EC channel 132 in a vicinity of first and second sensing coils 134 and 136. In the exemplary embodiment, drive coil 138 extends around first and second sense coils 134 and 136 and forms EC channel 132.
To enhance scanning of a relatively large surface area, an array of EC channels 132 is employed. Accordingly, the exemplary omni-directional EC probe 130 includes a number of EC channels 132 and a number of drive coils 138. Specifically, in the exemplary embodiment, at least one drive coil 138 is provided for each EC channel 132.
In the exemplary embodiment, the overlapping orientation of first and second sense coils 134 and 136 enables omni-directional EC probe 130 to detect imperfections in a sample being tested anywhere along the (Y) direction. However, omni-directional EC probe 130 may include any orientation of EC channels 132 that enables EC probe 130 to function as described herein. By including a plurality of EC channels 132 that are substantially identical, performance of the plurality of EC channels 132 is facilitated to be substantially uniform.
As described above with respect to EC probe 70, omni-directional EC array probe 130 is used to detect surface, or near surface, cracks (i.e., surface connected flaws) in conductive components, such as, but not limited to, aircraft engine components including disks, spools, and blades. Exemplary components are formed of nickel alloys and titanium alloys. However, EC probe 130 may be used with a variety of conductive components.
Operationally, drive coil 138 excites and generates a magnetic flux (i.e., probing field). The magnetic field influx into a conductive test object (not shown in
In the exemplary embodiment, first sense coil 134 has a positive polarity and second sense coil 136 has a negative polarity. The exemplary omni-directional EC probe 130 also includes electrical connections 142 that electrically couple first and second sense coils 134 and 136 together. In one embodiment, the electrical connections 142 are configured to perform both differential sensing (indicated by “DIFF”) and absolute sensing (indicated by “ABS”). Beneficially, the inclusion of both differential and absolute sensing features facilitates the detection of both small and long cracks.
First and second sense coils 134 and 136 form each EC channel 132 and have opposite polarity (indicated by “+” and “−”), and electrical connections 142 electrically couple first and second sense coils 134 and 136 within each respective EC channel 132. Drive coils 138 have alternating polarity with respect to adjacent drive coils 138 (also indicated by “+” and “−”). The polarity of first and second sense coils 134 and 136 alternates correspondingly with respect to adjacent EC channels. For example, those sense coils 134 and 136 within the middle EC channel 132 have the opposite polarity relative to those sense coils 134 and 136 in the upper and lower EC channels 132.
In an alternative embodiment, each EC channel 132 includes a sensor. For example, in one embodiment, the sensor is a solid-state sensor, such as, but not limited to, a Hall sensor, an anisotropic magnetic resistor (AMR), a giant magnetic resistor (GMR), a tunneling magnetic resistor (TMR), an extraordinary magnetoresistor (EMR), and/or a giant magnetoimpedance (GMI). However, any unpackaged solid-state sensor that enables eddy current testing as described herein may be used.
An omni-directional EC array probe 240 is initially positioned on calibration block 200. Probe 240 is then calibrated by moving probe 240 relative to calibration block 200 while measuring a voltage detected by the sensing coils (shown in
ADR process 280 also performs 284 an EC test of the component and produces a test image (not shown in
More specifically, in the exemplary embodiment, an algorithm decomposes the raw test image into various frequency sub-bands in the wavelet domain. The sub-bands are then subjected to a plurality of noise filters and adaptive thresholds, that are customized to the signal content of the sub-band under consideration. The use of appropriate sub-bands enhances the flaw response signature and thereby facilitates improving detectability and reducing the possibilities of false positives as compared to applying conventional rigid threshold segmentation schemes on the raw test data. ADR process 280 also includes compensating 288 the processed test image to correct for various signal levels detected, depending on the geometry of the detected defect.
ADR process 280 also includes calculating 290 an estimation of the size of a detected defect. The estimation of the size of the detected defect is based on the processed test image after compensating 288 which provides for higher accuracy of the size estimate while limiting false indications of a defect. The estimation of the size of the detected defect is then compared to a threshold value. If the estimated size of the detected defect is higher than the threshold value, a defect is noted. If the estimation of the size of the detected defect is lower than the threshold value, no defect is noted. Threshold values are calculated by PoD analysis.
In the exemplary embodiment, compensating 288 (shown in
In the exemplary embodiment, compensating 288 (shown in
Compensating 288 corrects partial defect responses, such as, for example, plot 344 of first Vpp, plot 346 of second Vpp, and plot 348 of third Vpp, so as to produce one single maximum defect response, for example, maximum Vpp 310 and sum 350. As described above, maximum Vpp 310 and sum 350 are used to predict the size of the defect.
In summary, the ADR process described herein facilitates the identification and segmentation of the flaw responses amidst various forms of electronic noise and part geometry indications using an adaptive thresholding scheme. Flaws of different orientations respond differently to the WASP array, both in terms of maximum amplitude of the response and in terms of its signature. The ADR process performs a compensation of image data corresponding to various flaw orientations to facilitate maximizing the extracted probe response. Once segmented, the flaw orientation is estimated in order to extract the appropriate maximum response.
As described above, the ADR process does not require prior information in the form of look-up tables, threshold values, or reference images. The image processing with the use of the wavelet decomposition has improved small crack detection, which facilitates improved PoD. The algorithm decomposes the image into various frequency sub-bands in the wavelet domain. The sub-bands are then subjected to a cascade of noise filters and adaptive thresholds, which are customized to the signal content of the sub-band under consideration. The use of appropriate sub-bands offers the advantage of enhancing the flaw response signature, while not simultaneously enhancing a level of noise, thereby facilitating improving a signal to noise ratio (SNR), detectability, and reducing the possibilities of false positives. This provides improvement over the conventional rigid threshold segmentation schemes on the raw data.
The compensation schemes apart from maximizing flaw responses, can estimate orientation of the flaw segmented. The peak-to-peak response is calculated for each region. Based on the orientation, the appropriate compensation is applied to facilitate deriving a maximum flaw response.
Improved defect characterization capability has been achieved by using a multivariate linear transformation to predict equivalent defect size. The multivariate equation is derived from regression analyses of various features extracted from the segmented region. The features used include maximum amplitude, number and polarity of peaks, energy of the segment and other derived features. Based on these features a transfer function has been developed that directly predicts the equivalent size of the detected defect.
By providing small flaw detection ability and reduced false positives, ADR process consequently improves the PoD. Use of the appropriate wavelet facilitates enhancing the flaw signature, while suppressing noise. Reductions in false identification of defects directly impact the First Time Yield (FTY) of the inspection. A poor FTY can negate any advantages WASP might provide in terms of inspection time.
Exemplary embodiments of eddy current inspection processes and systems are described above in detail. The processes and systems are not limited to the specific embodiments described herein, but rather, components of each system may be utilized independently and separately from other components described herein. Each system component can also be used in combination with other system components. More specifically, although the processes and systems herein are described with respect to inspection of aircraft engine components, it should be appreciated that the processes and systems can also be applied to a wide variety of components used within a steam turbine, a nuclear power plant, an automotive engine, or to inspect any mechanical component.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IN2007/000609 | 12/28/2007 | WO | 00 | 8/23/2010 |