Project: Turbine Blade Integrity Analysis
Advanced non-destructive testing for next-generation aerospace turbine components.
The Challenge
A leading aerospace manufacturer required a comprehensive integrity assessment of a new batch of single-crystal nickel superalloy turbine blades. These components are designed for operation in extreme thermal and mechanical stress environments exceeding 1,500°C. Initial quality control flagged potential subsurface anomalies that standard X-ray could not definitively characterize, risking catastrophic failure if undetected.
Our Solution & Process
We deployed a multi-modal NDT approach, beginning with phased-array ultrasonic testing (PAUT) to map the internal structure in high resolution. This was followed by eddy current testing (ECT) to detect surface-breaking cracks and micro-fissures in the complex cooling channel geometry.
- Phase 1: Detailed 3D scanning and digital twin creation of the blade geometry.
- Phase 2: High-frequency PAUT to identify and size suspected voids and inclusions.
- Phase 3: Precision ECT focusing on trailing edges and internal cooling passages.
- Phase 4: Cross-sectional micro-hardness mapping to verify heat treatment uniformity.
Key Results & Impact
-
1
Identified and precisely located 3 sub-critical inclusions in 2 out of 50 sample blades, allowing for targeted remediation.
-
2
Confirmed the structural integrity of the remaining 48 blades, providing the manufacturer with the data needed for final certification and assembly.
-
3
Delivered a complete digital report with interactive 3D flaw maps, reducing the client's internal review time by 40%.
Project Details
- Client
- Aerospace Turbine Systems
- Sector
- Aerospace Propulsion
- Material
- Single-Crystal Ni-based Superalloy
- Techniques
- PAUT, ECT, Micro-hardness
- Timeline
- 4 Weeks
Project Visuals
Turbine blade sample under controlled lighting for visual inspection.
Laboratory setup for non-destructive testing analysis.
This project exemplifies our capability to handle high-stakes, precision-critical analysis for advanced aerospace materials.
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