Non-Destructive Inspection (NDI) for recrystallized grains in single crystal superalloys Navy SBIR FY2013.2 Sol No.: Navy SBIR FY2013.2 Topic No.: N132-097 Topic Title: Non-Destructive Inspection (NDI) for recrystallized grains in single crystal superalloys Proposal No.: N132-097-0781 Firm: Texas Research Institute Austin, Inc. 9063 Bee Caves Road Austin, Texas 78733-6201 Contact: Mark Warchol Phone: (512) 263-2101 Web Site: www.tri-austin.com Abstract: Recently, the F-35 program experienced fatigue cracking in a low pressure turbine blade inside the F135 engine from recrystallization (RX). These problems cost the program time and money, strain the political capital necessary to sustain a large weapons program, and undermine the confidence of domestic and international partners. In response, TRI/Austin proposes utilizing an ultrasonic acoustic birefringence NDI technique to ensure turbine blade quality control. Instances of RX will be identified in single crystal superalloys through the changes in density as interpreted by transducers as the ultrasonic waves are sent through the part. To validate this approach, TRI/Austin will team with the Advanced Manufacturing Center (AMC) at the University of Texas at Austin. AMC will fabricate a set of NDI specimens with controlled incidents of RX introduced via deforming the specimens to introduce plastic strain before relieving in a vacuum furnace. The goal of these activities is a design for an inspection system at Pratt & Whitney to provide immediate go/no-go for the turbine blades as they are received from the casting house in Phase II, validated by testing against a set of specimens with controlled RX. Benefits: The F-35 program is projected to have an average yearly cost of $12.5 billion dollars with an estimated program life cycle cost of $1.1 trillion through 2050. Additionally, full rate production has slipped to 2019, a delay of 6 years off the original 2007 program timeline. There has been a great deal of political interest in this program due to its scope, solutions to many of the production delays need to be immediately addressed. Quality control issues with turbine blade recrystallization are not isolated to single crystal turbine blades in fighters. Commercial aircraft require also high strength, creep resistant materials to be able to withstand the temperatures inside of their engines and need quality assurance mechanisms to prevent loss of aircraft and life. Additionally, NDI validation programs and appropriate specimens are required to ensure the inspection systems work as desired. Finally, as the military continues to retire aging aircraft weapon systems, it is likely that the new aircraft will benefit from inspections such as these performed on next generation turbine blades to ensure that the programs stay on track, on budget, and that the aircraft can successfully perform in the air. Return