Generic Bolt Hole Eddy Current Testing Probability of Detection Study
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1 Generic Bolt Hole Eddy Current Testing Probability of Detection Study NRC-IAR, DND, TRI/Austin Catalin Mandache NDE Group, Structures and Materials Performance Laboratory
2 Outline Background Project objectives Design of experiments Experimental results Numerical-based PoD Approach Considered variables Example: Implementation of modelling results into the PoD
3 Project Objectives - Generate generic PoD data that could be used for future estimates of PoD for a range of similar constructions - Validate the currently used 90-95% discontinuity size in fastener bolt holes of aircraft wing box structures when using a DND eddy current inspection procedure - Use of numerical modelling to estimate PoD for similar structures and assess variability
4 Design of Experiments - A large number of inspectors and trainees was used for this study (following the same calibration, inspection, and recording procedures) - 1,434 coupons made of 7075-T6 aluminum alloy coupons contained laboratory-grown fatigue cracks coupons contained EDM notches coupons were kept blank - Four defect configurations each configurations contained 468 inspection sets (72 fatigue cracks and 45 EDM notches) - Real aircraft specimens containing EDM notches and overload cracks (Wing Splices: 35 cracked holes in 78 bolt holes and Web Stiffeners: 40 EDM notches in 151 bolt holes) fatigue cracks were not available
5 Design of Experiments Configuration #1 Configuration #7 c a c a Configuration #5 Configuration # a c a c
6 Design of Experiments
7 Summary of results a 90/95 PoD results ( hit-miss data) using the log-logistic method (MIL-HDBK ): Configuration #1: average / maximum (0.43mm/0.77mm) Configuration #5: average / maximum (0.30mm/0.55mm) Configuration #7: average / maximum (0.40mm/0.87mm) Configuration #12: average / maximum (0.63mm/0.83mm) For actual aircraft specimen: average / maximum (2.59mm/4.50mm)
8 Summary of results avg. a-hat Predicted depth 'c' (inches) Mid-bore cracks (configuration # 12) were used for the modelling example. Averaged results over 7 inspectors.
9 Summary of results Mid-bore cracks (configuration # 12) were used for the modelling example.
10 Numerical modelling for PoD - Represents an inexpensive alternative to costly experimental PoD studies - Has the potential to partially substitute and complement experimental PoD data - Reduces cost, effort, resources - Assures portability of PoD information across similar structures - Helps in damage tolerance calculations and increases platform availability Conditions: - Validate model on a reduced set of specimens - Use the same variables as the experimental study - Simulate the same signal features of interest
11 Numerical modelling for PoD Modelling software: - ECISM by CNDE and NDE Technologies - based on boundary element method - single layer - planar geometries - no crack width Input parameters: - probe geometry - crack dimensions - material properties - eddy current instrument settings
12 Numerical modelling for PoD
13 Evaluated variables Probe Crack Material Name of variable frequency lift-off tilt off-centre length depth length and depth rectangular versus elliptical shape electrical conductivity
14 Examples
15 Numerical-based approach General principles of using numerical-based approach for estimating PoD
16 Example Consider only a change in the driving frequency:
17 Example
18 Example
19 Summary Numerical modelling: - Insight into inspectability / detectability factors - inspection optimization - interpretation of results - Cost-reduction tool for extensive PoD studies - PoD studies based on a limited number of inspections - transportability of known PoD results to similar inspection situations Future work: - Validation of the predicted results - Establish new noise levels and threshold limits - Inclusion of the results in the PoD analysis
20 Contact info If you have questions regarding the overall project, please address them to: Dr. Abbas Fahr (NRC-IAR): Capt. DJ Butcher (DND-ATESS): Final Results to be presented at ASIP 2007, December 4-6
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