Inspection of butt welds for complex surface parts using ultrasonic phased array

Area of Science:

• Materials Science
• Mechanical Engineering
• Non-Destructive Testing

Background:

• Detecting weld defects in complex geometries is challenging due to transducer arrangement and acoustic beam path determination issues.
• Engine blade butt welds represent a critical application area for inspecting complex surface parts.

Purpose of the Study:

• To develop and validate an ultrasonic array testing method for full-coverage inspection of butt welds in complex surface parts.
• To address the geometric complexities that hinder traditional ultrasonic testing methods.

Main Methods:

• Analysis of acoustic wave propagation using Snell's law and acoustic pressure reciprocating transmittance (APRT).
• Iterative design of wedge parameters for multi-array transducers across divided inspection zones.
• Finite element method (FEM) modeling to simulate ultrasonic array response.

Main Results:

• A full-coverage inspection solution using multi-array transducers was established.
• FEM simulations validated the feasibility and effectiveness of the proposed inspection scheme.
• Experimental results on linear friction welded (LFW) engine blade specimens accurately detected prefabricated crack defects.

Conclusions:

• The developed ultrasonic array testing method provides rapid and accurate inspection for butt welds in complex surface parts.
• The method overcomes geometric challenges inherent in traditional ultrasonic testing for such components.
• This technique enhances the reliability of non-destructive testing for critical engine components.