1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2012 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside U
4、SA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AMS2636 AEROSPACE MATERIAL SPECIFICATION AMS2636 Issued 2012-09 Ultrasonic Immersion Inspecti
5、on Titanium and Titanium Alloy Forgings Premium Grade RATIONALE AMS2636 is a new specification that provides requirements for the ultrasonic inspection of titanium forgings used for critical, rotating engine components. 1. SCOPE 1.1 Purpose This specification covers procedures for ultrasonic immersi
6、on inspection of premium grade wrought titanium and titanium alloy forgings. Premium grade is a term used to describe titanium alloys used for critical rotating components in turbine engines. For details, see SAE AMS2380, the specification that covers the procedures for approval of products of premi
7、um-quality titanium alloys and the controls to be exercised in producing such products. 1.2 Application This inspection procedure is intended for use in locating internal defects such as cracks, voids, inclusions, and other structural discontinuities that may or may not be exposed to the surface in
8、forgings, but usage is not limited to such applications. Testing normally will be by longitudinal wave procedure, but shear wave procedure may be added when agreed upon by purchaser and vendor. 1.3 Classes Class A Acceptance based on signal-to-noise and amplitude (see Table 1) Class B Acceptance bas
9、ed on amplitude only (see Table 1) 1.4 Sensitivity Inspection sensitivity shall be defined in relation to the flat-bottomed hole (FBH) size used for acceptance, i.e., a sensitivity level of 1 would be used to note a #1FBH (1/64” diameter flat bottom hole) inspection. Unless otherwise specified, a se
10、nsitivity level of #1FBH inspection shall be used (See 4.1). If units other than 1/64 inchincrements are used, they shall be clearly defined in the purchase documentation. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without
11、license from IHS-,-,-SAE AMS2636 Page 2 of 15 2. APPLICABLE DOCUMENTS The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific doc
12、ument issue is specified. When the referenced document has been cancelled and no superseding document has been specified, the last published issue of that document shall apply. 2.1 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-
13、2959, Tel: 610-832-9585, www.astm.org. ASTM E 317 Evaluating Performance Characteristics of Ultrasonic Pulse-Echo Testing Systems Without the Use of Electronic Measurement Instruments ASTM E 428 Standard Practice for Fabrication and Control of Metal, Other than Aluminum Reference, Blocks Used in Ult
14、rasonic Examination ASTM E 1065 Evaluating Characteristics of Ultrasonic Search Units ASTM E 1316 Standard Terminology for Nondestructive Testing 2.2 ANSI Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.
15、 ANSI B46.1 Surface Texture 2.3 AIA Specifications Available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel: 703-358-1000, www.aia-aerospace.org. NAS 410 Certification and Qualification of Nondestructive Test Personnel 2.4 EN Documents Availab
16、le from the British Standards Institute, 389 Chiswick High Road, London, W4 4AL, United Kingdom, Tel: +44 (0)20 8996 9001, www.bsi-. BS EN 4179 Qualification and Approval of Personnel for Nondestructive Testing 3. TECHNICAL REQUIREMENTS 3.1 Qualification 3.1.1 Personnel Inspection of parts by this i
17、nspection process shall be accomplished by qualified personnel having experience with ultrasonic inspection. Qualification of personnel shall be in accordance with NAS 410, or BS EN 4179. Interpretation and evaluation of indications shall be accomplished by a Level 2 inspector or higher. Copyright S
18、AE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AMS2636 Page 3 of 15 3.1.2 Facilities Facilities shall be subject to review and approval by purchaser. Reference specifications, procedures, and documentation
19、 necessary to verify the qualification of equipment and test personnel shall be available to purchaser upon request. 3.2 Scan Plans and Written Inspection Procedures Ultrasonic inspections performed in accordance with this specification shall be detailed in written procedures that are applicable to
20、a broad class of forging inspections or part specific instructions. Inspection procedures shall be prepared by the vendor and approved by purchaser. Specific criteria and instructions required by the Cognizant Engineering Organization (CEO) shall be met. Inspection procedures shall include not less
21、than the following information: 3.2.1 Procedure identification number and the date the procedure was approved 3.2.2 Forging identifier, such as part number and alloy. 3.2.3 Equipment to be used, including manufacturer and model number of the instrumentation/system, recording equipment, alarm equipme
22、nt, electronic distance-amplitude correction (DAC) / Time Corrected Gain (TCG) equipment, and software and software version numbers. 3.2.4 Description of manipulating and scanning equipment 3.2.5 Inspection configuration including inspection sonic shape, sound entry angle, entry surfaces, water path
23、 distance(s), and number of scans per zone. 3.2.6 Amplitudes for calibration, evaluation threshold, and reject limits. 3.2.7 Rotational speed and index. 3.2.8 Pulse repetition rate or specify “Pulse on Position“ 3.2.9 Reference standard description including material, dimensions, reflector size, tes
24、t metal distance, and correction factors where applicable. 3.2.10 Method used for distance amplitude corrections. 3.2.11 Method for attenuation correction. 3.2.12 Gate length and delay per zone, if applicable. 3.2.13 Methods for surface preparation and surface texture control. 3.2.14 Transducer desc
25、ription including frequency, element diameter, and nominal focus information 3.2.15 Zoning schemes as applicable, as described in Appendix B. 3.3 Exceptions No exception shall be taken to the written procedure or this specification unless approved by purchaser. Copyright SAE International Provided b
26、y IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AMS2636 Page 4 of 15 3.4 Equipment 3.4.1 Ultrasonic Instrument The ultrasonic instrument shall be capable of producing, receiving, and displaying electrical pulses at the required frequ
27、encies and energy levels. The instrument shall be able to operate in the pulse-echo mode at frequencies of 2.25 through 10 MHz. Gates, distance-amplitude correction system, and other electronic aids to ultrasonic testing and interpretation shall be used as required. An alarm system, auto-stop, recor
28、der, or combination of these may be used. 3.4.1.1 Instrument Performance The vertical limit and linearity, and the accuracy of calibrated gain controls shall be evaluated in accordance with ASTM E 317 with the following requirements and exceptions. Substitute performance checks are permissible when
29、agreed upon by purchaser and vendor. 3.4.1.1.1 Vertical linearity shall be 1 dB over the range of 10 to 90% of full scale. 3.4.1.1.2 Accuracy of calibrated gain control shall be within 2 dB over the usable range of the instrument. 3.4.2 Ultrasonic Transducers (Search Units) Transducers shall be eval
30、uated in accordance with ASTM E 1065 to determine frequency response, peak frequency, and band width. The peak frequency shall be not less than 4 MHz. Transducers shall be tested to determine the beam width. The beam width shall be determined in two directions perpendicular to one another as appropr
31、iate to establish the scan index used as defined in 3.8.3. The beam width measurements should be performed using flat-bottom hole targets close to the focal plane of the transducer, in reference standards such as those listed in Appendix A. Typical inspection zones and associated transducer descript
32、ions for Class A and Class B inspections are provided in Appendix B. 3.4.3 Voltage Regulator The line voltage shall not produce variations in signal response or noise which could interfere with the inspection. 3.4.4 Couplant Clean water shall be used as the couplant material; rust inhibitors, wettin
33、g agents, or both, may be added. The water shall be free of visible air bubbles which may interfere with the ultrasonic test. 3.4.5 Data Acquisition System If a digital data acquisition system is used to record the data, it shall meet the requirements listed in 3.4.5.1 to 3.4.5.6. 3.4.5.1 Components
34、 The system shall consist of encoders for axes of programmable motion, an analog-to-digital (A/D) signal conversion device, a computer, display monitor, an archival storage system, and appropriate software. 3.4.5.2 A/D Conversion For each pulse, the peak ultrasonic amplitude in the gated region of e
35、ach inspection zone shall be digitized to a minimum resolution of 8 bits over the full range of amplitudes used for data acquisition. The A/D converter shall be adjusted using procedures recommended by the manufacturer. 3.4.5.3 Recording System Linearity Recording system shall be shown to reproduce
36、recorded amplitude data to an accuracy of 2% of full scale. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AMS2636 Page 5 of 15 3.4.5.4 Digital Data Storage Digital amplitudes and the correspond
37、ing encoder positions shall be stored. For each ultrasonic amplitude, the corresponding encoder positions shall be retrievable by the operator for relocation and evaluation of indications. Data storage system shall provide traceability of the position of indications relative to the forging inspectio
38、n surface. 3.4.5.5 Digital Data Archiving When required by the purchaser, all inspection digital data files shall be archived and accessible on storage media acceptable to purchaser. 3.4.5.6 Analysis of Digital Data Software to analyse the digital data shall perform not less than the following funct
39、ions: display location and amplitude of indications above the evaluation threshold; allow selection of region of interest (ROI); and calculate the maxium signal, mean noise and peak noise to enable signal-to-noise ratio per 4.1.1 when required for Class A inspections. 3.4.6 Reference Standards 3.4.6
40、.1 Manufacture of Reference Standards Reference standards may be as defined by the CEO. If not defined by the CEO, reference standards shall be manufactured and certified to ASTM E 428. 3.4.6.2 Fabrication of Flat Bottom Holes (FBH) Unless otherwise specified by the CEO, FBHs shall be a maximum of 1
41、/64-inch diameter and certified to ASTM E428. FBH depths shall encompass the necessary near surface resolution and the depth of the intended inspection. Recommended FBH depths for multizone and conventional inspection are shown in Appendix A. A distance-amplitude response curve shall be plotted as g
42、ain vs FBH depth for each set of reference standards. An example is shown in Figure 1, below. For an acceptable set of reference standards, no point shall be more than 2 dB from a best fit curve. After dimensional check, FBH openings may be plugged, leaving an air pocket at the flat bottom hole end.
43、 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AMS2636 Page 6 of 15 04812162024283236400 1 2 3 4 5FBH de pthRelative amplitude (dB)2dBFIGURE 1. RELATIVE FBH AMPLITUDE (DB) AS A FUNCTION OF FBH
44、DEPTH FOR ACCEPTABLE REFERENCE STANDARDS. 3.4.6.3 Selection of Material for Reference Standards When not specified by the CEO, material used to fabricate reference standards shall be made from a base alloy similar to the parts to be inspected. All reference standards shall be made from forgings (wro
45、ught material) of homogeneous structure. The material used for reference standards shall be free of discrete ultrasonic discontinuity indications greater than twice the noise level. Consistency of the material attenuation characteristics for each set of reference standards shall be assured by determ
46、ining the amount of gain that is required to raise the first backwall signal to a selected frontwall signal amplitude for each thickness. Results shall be plotted as dB vs. material thickness and a best fit line shall be drawn through the points as in Figure 2. For an acceptable set of reference sta
47、ndards no point shall be more than 2 dB from this line. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AMS2636 Page 7 of 15 481216202428320 1 2 3 4 5block thicknessRelative amplitude (dB)2dBFIGU
48、RE 2. RELATIVE FIRST-BACKWALL AMPLITUDE (DB) AS A FUNCTION OF REFERENCE STANDARD THICKNESS. 3.4.6.4 Reference standards shall be subject to calibration, certification, and recall procedures required by purchaser. 3.4.7 System Operation (Dynamic Response) The total system shall have dynamic response adequate to provide correct amplitude data for all inspection scan and recording parameters. 3.5 Surface Preparation 3.5.1 Surfaces to be inspected shall not produce ultrasonic reflections which interfere with the test. Acceptable surface roughness
