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POD of NDT Techniques Using High Temperature Oxidized Fatigue Cracks in an Aero Engine Alloy

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Abstract

Establishing probability of detection (POD) or reliability of various nondestructive testing (NDT) techniques is essential for implementing damage tolerant (DT) methodology for aero-engines. This POD is usually established with the help of a large number of service expired aero-engine components containing several fatigue cracks. In the absence of such components, artificial defects such as electrical discharge machining (EDM) notches or starter cracks were explored. However, such artificial defects would not meet the key features such as tightness of the fatigue cracks and the possible oxidation in the crack opening and thus, limiting their usage. Therefore, in the current study, an innovative approach of generating fatigue cracks at 650 °C (~ typical aero-engine service temperatures) with key high temperature service degradation aspects of oxidation and fatigue cracking is demonstrated for the first time using Gleeble® test system. Further, POD is estimated by inspecting these laboratory generated fatigue cracks using fluorescent liquid penetrant technique (FLPT) and eddy current technique (ECT) under HIT (defect detected) vs. MISS (defect not detected) and â (signal response) vs. a (crack size) methodologies. The current study also discusses a statistical approach of random generation of crack sizes for use in NDT reliability analysis. In addition, an attempt has been made to understand the effect of a90/95 values on remnant life calculations. It is concluded that the eddy current response of oxidized fatigue cracks results in better (high sensitive) a90/95 values compared to the eddy current response obtained from non-oxidized fatigue cracks.

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Acknowledgements

The authors express their gratitude to Director, DMRL (Defence Metallurgical Research Laboratory) for the encouragement provided to publish this work. The funding provided by Defence Research and Development Organization (DRDO) to carry out the work is acknowledged. Authors would also like to thank DST-FIST and DST-PURSE grant for the FESEM-EDS-EBSD facility and its maintenance at School of Engineering Science and Technology, University of Hyderabad. One of the authors, Dr. T. Jayakumar, DRDO Prof. S. Bhagavantham Chair, would like to express his gratitude to DRDO. The authors would also like to thank Dr. Ashok Kaul, CEO, LPTI Inc., Canada for many useful discussions in identifying the problem. Extensive support of Mr. Lambodar Sahoo, STA ‘B’, DMRL in testing the samples using Gleeble® Test System is appreciated. One of the authors, Mr. Vamsi Krishna Rentala is also thankful to the Council of Scientific and Industrial Research (CSIR) for providing Senior Research Fellowship (ACK. No.: 141308/2k15/1, File No.: 09/414(1124)/2016 EMR-I).

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Authors and Affiliations

  1. School of Engineering Sciences and Technology, University of Hyderabad, Hyderabad, 500046, India

    Vamsi Krishna Rentala & Jai Prakash Gautam

  2. Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad, 500058, India

    Phani Mylavarapu, Atul Kumar, K. Gopinath & T. Jayakumar

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  1. Vamsi Krishna Rentala
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  2. Phani Mylavarapu
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  3. Atul Kumar
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  4. Jai Prakash Gautam
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  5. K. Gopinath
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Contributions

Planning, execution, analysis and original draft preparation: VKR, conceptualization, formal analysis, writing—review and editing: PM, methodology and resources: AK, supervision: JPG, methodology, resources and writing-review and editing: KG, conceptualization, methodology, writing-review: TJ.

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Correspondence to Phani Mylavarapu.

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Rentala, V.K., Mylavarapu, P., Kumar, A. et al. POD of NDT Techniques Using High Temperature Oxidized Fatigue Cracks in an Aero Engine Alloy. J Nondestruct Eval 40, 41 (2021). https://doi.org/10.1007/s10921-021-00769-7

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