Objective
TO STUDY THE FLAW GENERATION AS THE TURBINE PART PROCESSING PROCEDS.
NON-DESTRUCTIVE TESTS WILL BE PERFORMED ON INJECTION MOULDED GREEN AND SINTERED PARTS, SUCH AS PRISMATIC BEND-TEST BARS, AXIAL TIRBINE BLADES AND RADIAL TURBINE ROTORS (EXHAUST GAS TURBOCHARGERS).
THE INSPECTION WILL BE PERFORMED AT THREE DIFFERENT STAGES IN THE PROCESS:
1. AFTER INJECTION MOULDING
THE MOULDED PARTS CONSIST OF A SOLID PLASTIC BINDER MIXTURE WHICH IS HIGHLY LOADED WITH FINE CERAMIC POWDER. FLAWS LIKE AIR PORES, SHRINKAGE CAVITIES, RESIDUAL STRESSES, ETC. ARE TO BE DETECTED.
2. AFTER BINDER REMOVAL
AT THIS STAGE THE PART CONSISTS OF A CERAMIC-PARTICLE NETWORK AND OPEN VOID SPACE. SURFACE AND INNER FLAWS - ESPECIALLY CRACKS - CAN OCCUR AS A FUNCTION OF PLASTIC BINDER COMPOSITION AND COMPONENT TICKNESS.
3. AFTER SINTERING
THE DENSE SINTERED PARTS CONSIST OF AN ALMOST PURE SIC CERAMIC.
SHRINKAGE CAVITIES, CRACKS, MICROSTRUCTURAL INHOMOGENEITIES LIKE PORE CLUSTERS, DENSITY GRADIENTS, INCLUSIONS OF FOREIGN PARTICLES ETC., ARE TO BE DETECTED.
THE ND-METHODS TO BE USED ARE:
- CONVENTIONAL X-RAY RADIOGRAPHY TOGETHER WITH NEW HIGH RESOLUTION X-RAY TESTING METHODS BY FILM EVALUATION FOR STRUCTURE AND DEFECT ANALYSIS,
- LOW AND HIGH FREQUENCY ULTRASONIC TESTING FOR FLAW DETECTION,
STRUCTURE AND STRESS ANALYSIS,
- VIBRATION ANALYSIS FOR CHARACTERIZATION OF SINTERED PRODUCTION LOTS OF TURBINE COMPONENTS,
- PHOTOACOUSTIC AND PHOTOTHERMIC MICROSCOPY (SLAM, SPAM) WITH HIGH RESOLUTION.
FOR THE VARIOUS ND-TESTS ESK IS DELIVERING NOT ONLY TYPICAL "STATE OF ART" PRODUCTION LOTS BUT ALSO SEEDED-FLAW PARTS. THIS WILL PERMIT SYSTEMATIC STUDY OF DIFFERENT TYPES, SIZES, LOCATIONS AND FREQUENCIES OF DEFECTS.
FOR TESTING AND FURTHER DEVELOPMENT OF ND-TECHNIQUES THE MAX PLANCK INSTITUT, PHILIPS, BALTEAU AND BRUEL & KJAER WILL BE INVOLVED.
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Programme(s)
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Coordinator
80331 München
Germany
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