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5.1 PCRT Applications and Capabilities—PCRT has been applied successfully to a wide range of NDT applications in the manufacture and maintenance of metallic and non-metallic parts. Examples of anomalies detected are discussed in 1.1. PCRT has been shown to provide cost effective and accurate NDT solutions in many industries including automotive, aerospace, and power generation. Examples of successful applications currently employed in commercial use include, but are not limited to:(1) Silicon nitride bearing elements(2) Steel, iron, and aluminum rocker and control arms(3) Aircraft and industrial gas turbine engine components (blades, vanes, disks)(4) Cast cylinder heads and cylinder blocks(5) Sintered powder metal gears and clutch plates(6) Machined forged steel steering and transmission components (gears, shafts, racks)(7) Ceramic oxygen sensors(8) Silicon wafers(9) Gears, including those with induction hardened or carburized teeth(10) Ceramic matrix composite (CMC) material samples and components(11) Components with shot peened surfaces(12) Machined or rolled-formed fasteners(13) Components made with additive manufacturing(14) Aircraft landing gear, wheel, and brake components(15) Components made with metal injection molding5.2 General Approach and Equipment Requirements for PCRT via Swept Sine Input: 5.2.1 PCRT systems comprise hardware and software capable of inducing vibrations, recording the component response to the induced vibrations, and executing analysis of the data collected. Inputting a swept sine wave into the part has proven to be an effective means of introducing mechanical vibration and can be achieved with a high quality signal generator coupled with an appropriate active transducer in physical contact with the part. Collection of the part’s frequency response can be achieved by recording the signal generated by an appropriate passive vibration transducer. The software required to analyze the available data may include a variety of suitable statistical analysis and pattern recognition tools. Measurement accuracy and repeatability are extremely important to the application of PCRT.5.2.2 Hardware Requirements—A swept sine wave signal generator and response measurement system operating over the desired frequency range of the test part are required with accuracy better than 0.002 %. The signal generator should be calibrated to applicable industry standards. Transducers must be operable over same frequency range. Three transducers are typically used; one Drive transducer and two Receive transducers. Transducers typically operate in a dry environment, providing direct contact coupling to the part under examination. However, non-contacting response methods can operate suitably when parts are wet or oil-coated. Other than fixturing and transducer contact, no other contact with the part is allowed as these mechanical forces dampen certain vibrations. For optimal examination, parts should be placed precisely on the transducers (generally, ±0.062 in. (1.6 mm) in each axis provides acceptable results). The examination nest and cabling shall isolate the Drive from Receive signals and ground returns, so as to not produce (mechanical or electrical) cross talk between channels. Excessive external vibration or audible noise, or both, will compromise the measurements.5.3 Constraints and Limitations: 5.3.1 PCRT cannot separate parts based on visually detectable anomalies that do not affect the structural integrity of the part. It may be necessary to provide additional visual inspection of parts to identify these indications.5.3.2 Excessive process variation of parts may limit the sensitivity of PCRT. For example, mass/dimensional variations exceeding 5 % may cause PCRT to be unusable.5.3.3 Specific anomaly identification is highly unlikely. PCRT is a whole body measurement and differentiating between a crack and a void in the same location is generally not possible. It may be possible to differentiate some anomalies by using multiple patterns and training sets. The use of physics-based modeling and simulation to predict the resonance frequency spectrum of a component may also allow relationships between resonance frequencies and defect locations/characteristics to be established.5.3.4 PCRT will only work with stiff objects that provide resonances whose frequency divided by their width at half of the maximum amplitude (Q) are greater than 400 to 500. Although steel parts may be very stiff and perfectly reasonable to use for PCRT, steel foil would generally not be.5.3.5 While PCRT can be applied to painted and coated parts in many cases, the presence of some surface coatings such as vibration-absorbing materials and heavy oil layers may limit or preclude the application of PCRT.5.3.6 While PCRT can be applied to parts over a wide range of temperatures, it should not be applied to parts that are rapidly changing temperature. The part temperature should be stabilized before collecting resonance data.5.3.7 Misclassified parts in the teaching set, along with the presence of unknown anomalies in the teaching set, can significantly reduce the accuracy and sensitivity of PCRT.1.1 This practice describes a general procedure for using the process compensated resonance testing (PCRT) via swept sine input method for metallic or non-metallic parts to compare resonance patterns from a sample under test to reference teaching sets of known acceptable and targeted defect samples. The resonance pattern differences can be used to distinguish acceptable parts with normal process variation from parts with targeted material states and defects that will cause performance deficiencies. These material states and defects include, but are not limited to, cracks, voids, porosity, shrink, inclusions, discontinuities, grain and crystalline structure differences, density-related anomalies, heat treatment variations, material elastic property differences, residual stress, and dimensional variations. This practice is intended for use with instruments capable of exciting, measuring, recording, and analyzing multiple whole body, mechanical vibration resonance frequencies in acoustic or ultrasonic frequency ranges, or both.1.2 Units—The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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5.1 PCRT Applications and Capabilities—PCRT PTI examination has been applied successfully to a wide range of parts in manufacturing and maintenance environments. Examples of manufacturing processes, repair processes, and in-service damage mechanisms evaluated with PTI are discussed in 1.1. PCRT has been shown to provide cost effective and accurate PTI-based NDT, process monitoring, and life monitoring in many industries including automotive, aerospace, and power generation. Examples of successful applications currently employed in commercial use include, but are not limited to:(1) Heat treatment operations:(a) Aerospace gas turbine engine components (blades, vanes, disks)(b) Additively manufactured components(c) Steel mechanical components(d) Industrial gas turbine blades(2) Induction hardening and carburization (both case-hardened and through-hardened parts):(a) Gears(b) Ballnuts(3) Hot Isostatic Pressing (HIP):(a) Gas turbine engine components (blades, vanes, disks)(b) Additively manufactured components(4) Shot peening:(a) Steel mechanical components(5) In-service thermal history, aging, creep damage, fatigue:(a) Gas turbine engine components (blades, vanes, disks)(b) Industrial gas turbine blades(c) Aircraft landing gear wheels(6) Maintenance repair/rejuvenation processes:(a) Gas turbine engine components (blades, vanes, disks)(b) Industrial gas turbine blades(c) Aircraft landing gear wheels.5.2 General Approach and Equipment Requirements for PCRT via Swept Sine Input: 5.2.1 PCRT systems comprise hardware and software capable of inducing vibrations, recording the component response to the induced vibrations, and analyzing the data collected. Inputting a swept sine wave into the part has proven to be an effective means of introducing mechanical vibration and can be achieved with a high-quality signal generator coupled with an appropriate active transducer in physical contact with the part. Collection of the part’s resonance response is achieved by recording the signal received by an appropriate passive vibration transducer. The software required to analyze the available data may include a variety of suitable statistical analysis and pattern recognition tools. Measurement accuracy and repeatability are extremely important to the application of PCRT.5.2.2 Hardware Requirements—A swept sine wave signal generator and response measurement system operating over the desired frequency range of the test part are required with accuracy better than 0.002 %. The signal generator should be calibrated to applicable industry standards. Transducers must be operable over same frequency range. Three transducers are typically used; one Drive transducer and two Receive transducers. Transducers typically operate in a dry environment, providing direct contact coupling to the part under examination. However, noncontacting response methods can operate suitably when parts are wet or oil-coated. Other than fixturing and transducer contact, no other contact with the part is allowed as these mechanical forces dampen certain vibrations. For optimal examination, parts should be placed precisely on the transducers (generally, ±0.062 in. (1.6 mm) in each axis provides acceptable results). The examination nest and cabling shall isolate the Drive from Receive signals and ground returns, so as to not produce (mechanical or electrical) cross talk between channels. Excessive external vibration or audible noise, or both, will compromise the measurements.5.3 Constraints and Limitations: 5.3.1 PCRT cannot separate parts based on visually detectable anomalies that do not affect the structural integrity of the part. It may be necessary to provide additional visual inspection of parts to identify these indications.5.3.2 Excessive variation in part geometry or base material properties may limit the sensitivity of PCRT PTI examination.5.3.3 A direct measurement of a single geometric dimension of a region undergoing a material state change, such as the case depth (in centimeters or inches) of an induction hardened region, is generally not possible with PCRT PTI. The frequency changes are dependent on the total volumetric effect of the process that causes the material state change. With accurately trained acceptability limits, however, PCRT PTI is very effective at screening populations of components for acceptable and unacceptable processing.5.3.4 PCRT will only work with stiff objects that provide resonances whose peak quality factor (Q) values are greater than 500. Non-rigid materials or very thin-walled parts will not yield useful Q values.5.3.5 While PCRT can be applied to painted and coated parts in many cases, the presence of some surface coatings such as vibration absorbing materials and heavy oil layers may limit or preclude the application of PCRT.5.3.6 While PCRT PTI examination can be applied to parts over a wide range of temperatures, it cannot be applied to parts that are rapidly changing temperature. The part temperature should be stabilized before collecting resonance data.5.3.7 Misclassified parts in the teaching set, along with the presence of unknown anomalies in the teaching set, can significantly reduce the accuracy and sensitivity of PCRT.1.1 This practice covers a general procedure for using the Process Compensated Resonance Testing (PCRT) via swept sine input method to perform Part-to-Itself (PTI) examination on populations of newly manufactured and in-service parts. PCRT detects resonance pattern differences in metallic and non-metallic parts. Practice E2534 for Defect Detection with PCRT and Practice E3081 for Outlier Screening with PCRT cover the development and application of PCRT sorting modules that inspect a part at a single point in time. These methods use the resonance frequency spectra recorded from test parts and perform different statistical analyses to compare test parts to reference populations. These comparisons include, and must compensate for, the normal geometric, material, and processing variations present in any population of parts. In many applications, however, the user may need to evaluate the effects of a single processing step or in-service load in isolation from other sources of variation. For example, a manufacturer may want to perform process monitoring and control on a heat treatment or hardening process. A maintainer may want to evaluate the effect of service cycles in an engine. A PCRT PTI examination measures the resonance frequency spectrum of a part at two points in time, such as before and after a manufacturing process step, and calculates the change in resonance frequencies to evaluate the effect of the intervening process. Control limits can be set on the frequency change to field a PTI PASS/FAIL inspection capability. The limits may be based on training populations of parts with acceptable and unacceptable levels of change, model predictions of the effects of part changes, or criteria derived from process control practices. Manufacturing processes and in-service loads that can be evaluated with a PCRT PTI inspection include, but are not limited to heat treatment, hot isostatic pressing (HIP), shot peening, induction hardening, carburization, coating, thermal history changes, residual stress changes, creep, plastic deformation, corrosion, and fatigue. This practice is intended for use with instruments capable of exciting, measuring, recording, and analyzing multiple, whole body, mechanical vibration resonance frequencies in acoustic or ultrasonic frequency ranges, or both.1.2 Units—The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

定价: 590元 / 折扣价: 502 加购物车

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5.1 PCRT Applications and Capabilities—PCRT has been applied successfully to a wide range of outlier screening applications in the manufacture and maintenance of metallic and non-metallic parts. Examples of anomalies detected are discussed in 1.1. PCRT has been shown to provide cost effective and accurate outlier screening solutions in many industries including automotive, aerospace, and power generation. Examples of successful applications currently employed in commercial use include, but are not limited to:(1) Silicon nitride bearing elements,(2) Steel, iron, and aluminum rocker and control arms,(3) Aircraft and industrial gas turbine engine components (blades, vanes, disks),(4) Cast cylinder heads and cylinder blocks,(5) Sintered powder metal gears and clutch plates,(6) Machined forged steel steering and transmission components (gears, shafts, racks),(7) Ceramic oxygen sensors,(8) Silicon wafers,(9) Gears, including those with induction hardened or carburized teeth,(10) Ceramic matrix composite (CMC) material samples and components,(11) Components with shot peened surfaces,(12) Machined or rolled-formed steel fasteners, or both,(13) Components made with additive manufacturing,(14) Aircraft landing gear, wheel and brake components, and(15) Components made with metal injection molding.5.2 General Approach and Equipment Requirements for PCRT via Swept Sine Input: 5.2.1 PCRT systems are comprised of hardware and software capable of inducing swept sine vibrations, recording the component response to the induced vibrations, and executing analysis of the data collected. Inputting a swept sine wave into the part has proven to be an effective means of introducing mechanical vibration and can be achieved with a high quality signal generator coupled with an appropriate active transducer in physical contact with the part. Collection of the part’s frequency response can be achieved by recording the signal generated by an appropriate passive vibration transducer. The software required to analyze the available data may include a variety of suitable statistical analysis and pattern recognition tools. Measurement accuracy and repeatability are extremely important to the application of PCRT.5.2.2 Hardware Requirements—A swept sine wave signal generator and response measurement system operating over the desired frequency range of the test part are required with accuracy better than 0.002 %. The signal generator should be calibrated to applicable industry standards. Transducers must be operable over same frequency range. Three transducers are typically used; one “drive” transducer and two “receive” transducers. Transducers typically operate in a dry environment, providing direct contact coupling to the part under examination. However, noncontacting response methods can operate suitably when parts are wet or oil-coated. Other than fixturing and transducer contact, no other contact with the part is allowed as these mechanical forces dampen certain vibrations. For optimal examination, parts should be placed precisely on the transducers (generally, ±0.062 in. (1.6 mm) in each axis provides acceptable results). The examination nest and cabling shall isolate the drive from receive signals and ground returns, so as to not produce (mechanical or electrical) cross talk between channels. Excessive external vibration or audible noise, or both, will compromise the measurements.5.3 Constraints and Limitations: 5.3.1 PCRT cannot separate parts based on visually detectable anomalies that do not affect the structural integrity of the part. It may be necessary to provide additional visual inspection of parts to identify these indications.5.3.2 Excessive process variation of parts may limit the sensitivity of PCRT outlier screening.5.3.3 Specific anomaly identification is highly unlikely. PCRT is a whole body measurement, so differentiating between a crack and a void in the same location is generally not possible. It may be possible to differentiate some anomalies by using multiple patterns and teaching sets. The use of physics-based modeling and simulation to predict the resonance frequency spectrum of a component may also allow relationships between resonance frequencies and defect locations/characteristics to be established.5.3.4 PCRT will only work with stiff objects that provide resonances whose peak quality factor (Q) values are greater than 500. Non-rigid materials or very thin-walled parts may not yield satisfactory Q values.5.3.5 While PCRT can be applied to painted and coated parts in many cases, the presence of some surface coatings such as vibration absorbing materials and heavy oil layers may limit or preclude the application of PCRT.5.3.6 While PCRT can be applied to parts over a wide range of temperatures, it should not be applied to parts that are rapidly changing temperature. The part temperature should be stabilized before collecting resonance data.5.3.7 Misclassified parts in the teaching set, along with the presence of unknown anomalies in the teaching set, can significantly reduce the accuracy and sensitivity of PCRT.1.1 This practice describes a general procedure for using the process compensated resonance testing (PCRT) via swept sine input method to perform outlier screening on populations of newly manufactured and in-service parts. PCRT excites the resonance frequencies of metallic and non-metallic test components using a swept sine wave input over a set frequency range. PCRT detects and analyzes component resonance frequency patterns and uses the differences in resonance patterns between acceptable and unacceptable components to perform non-destructive testing. PCRT frequency analysis compares the resonance pattern of a component to the patterns of known reference populations of the same component and renders a pass or fail result based on the similarity of the tested component to those populations. For non-destructive testing applications with known defects or material states of interest, or both, Practice E2534 covers the development and application of PCRT sorting modules that compare test components to known acceptable and unacceptable component populations. However, some applications do not have physical examples of components with known defects or material states. Other applications experience isolated component failures with unknown causes or causes that propagate from defects that are beyond the sensitivity of the current required inspections, or both. In these cases, PCRT is applied in an outlier screening mode that develops a sorting module using only a population of presumed acceptable production components, and then compares test components for similarity to that presumed acceptable population. The resonance differences can be used to distinguish acceptable components with normal process variation from outlier components that may have material states or defects, or both, that will cause performance deficiencies. These material states and defects include, but are not limited to, cracks, voids, porosity, shrink, inclusions, discontinuities, grain and crystalline structure differences, density-related anomalies, heat treatment variations, material elastic property differences, residual stress, and dimensional variations. This practice is intended for use with instruments capable of exciting, measuring, recording, and analyzing multiple, whole body, mechanical vibration resonance frequencies in acoustic or ultrasonic frequency ranges, or both.1.2 Units—The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

定价: 590元 / 折扣价: 502 加购物车

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