Component inspection apparatus and method

A component inspection apparatus and a method for ultrasonic inspection of a component, including low pressure last stage steam turbine blades, are disclosed. The apparatus includes a guide member, a guide adapting member and scanning probes. The guide member includes a first surface and a distal second surface. The first surface is configured to adaptably mirror the shape of portions of the component to be inspected. The guide adapting member is capable of releasably attaching the second surface of the guide member. to be changeable as per the shape of the component. The scanning probes may be located on the guide adapting member in a manner configured to be movable along the second surface of the guide member to generate and receive ultrasonic waves used to inspect the component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to European application 13165902.1 filed Apr. 30, 2013, the contents of which are hereby incorporated in its entirety.

TECHNICAL FIELD

The present disclosure relates to a non-destructive material inspection, and, more particularly, to an apparatus and a method for ultrasonic inspection of components, including but not limited to, low pressure last stage steam turbine blades.

BACKGROUND

Non-destructive material inspection using ultrasonic waves for the detection of flaws in components are well known conventionally.

More often than not, challenges arrive while inspecting components, such as aerofoil, filet radius, and specifically, low pressure last stage steam turbine blades using ultrasonic techniques due to varying size, shapes and geometries, and compactness of the components with respect to each other. Generally, for ultrasonic inspection for turbine blades, conventionally known specialized tools are available that have varying shapes and designs and include probes. These conventionally known tools are inserted between the blades for inspection thereof. The probes release and receive ultrasonic waves from the blades to determine flaws in the blades. Among the various requirements for the accurate ultrasonic inspection of the blades by the conventional tool is the essential requirement of matching the tool profile with the blade profile. This requirement makes it essential to produce various tools with probes with respect to each individual blade profile adding to overall cost of inspection of turbine blades.

An example of a known tool is discussed in U.S. patent application no. 2007/0044564 A1. The tool comprises a sensor holder that is shaped to conform to the shape of a test body and further made of a material that enables rapid prototyping. By means of an adjustable corner portion the sensor holder's shape may be adjusted to take into account various widths of the test body along its length. The sensor fixed to the holder may be an ultrasonic inspection device.

Another example of a known tool is discussed in EP2096433A1. The tool comprises a rail for guiding the carriage that is used to hold a test heading configured for nondestructively material testing. The rail is made of, for example, epoxy resin thus enabling quickly manufactured of a rail that conforms to the surface shape of a test body. The rail further includes grooves in which guiding rollers of the carriage can be inserted, that guide the carriage along the length of the rail. This enables the testing head, which is mounted on the carriage, to direct a testing device along a defined path of the test body.

Such conventional tools may be quite in practice, and may have generally been considered satisfactory for their intended purposes, but may be unsatisfactory in terms of adaptability thereof with respect to varying shapes, size and geometries of the blades.

Accordingly, there exists a need for an ultrasonic inspection of components in an economical and adaptable manner.

SUMMARY

The present disclosure describes an apparatus and a method for ultrasonic inspection of a component, such as low pressure last stage turbine blades, that will be presented in the following simplified summary to provide a basic understanding of one or more aspects of the disclosure that are intended to overcome the discussed drawbacks, but not to include all advantages thereof, along with providing some additional advantages. This summary is not an extensive overview of the disclosure. It is intended to neither identify key or critical elements of the disclosure, nor to delineate the scope of the present disclosure. Rather, the sole purpose of this summary is to present some concepts of the disclosure, its aspects and advantages in a simplified form as a prelude to the more detailed description that is presented hereinafter.

An object of the present disclosure is to describe an apparatus and a method, which may be adaptable in terms of being modified for ultrasonic inspection of a component, such as low pressure last stage turbine blades of varying shapes, size and geometries. Another object of the present disclosure is to describe an apparatus and a method, which are convenient to use in an effective and economical way. Various other objects and features of the present disclosure will be apparent from the following detailed description and claims.

The above noted and other objects, in one aspect, may be achieved by an apparatus for ultrasonic inspection of a component. In other aspects, above noted and other objects, may be achieved by a method for ultrasonic inspection of a component. Examples of the components, where such apparatus and method may be utilized, include but is not limited to, low pressure last stage turbine blades, aerofoil and filet radius. While the disclosure will be described in conjunction with the turbine blades for the purpose of better understanding, the scope of the disclosure will extend to all such components where the present apparatus and method may be successfully utilized.

According to the above aspects of the present disclosure, a component inspection apparatus for ultrasonic inspection of a component is disclosed. The apparatus includes a guide member, a guide adapting member and scanning probes. The guide member has a first surface and a distal second surface. The first surface is configured to adaptably mirror a shape of a portion of the component, such that the guide member is adaptably changeable to the shape of a portion of the component while the second surface has a length between distal ends of the surface. The guide adapting member is adapted to be releasably attached to the second surface of the guide member so that during testing the guide adapting member and the guide member do not move relative to each other. The scanning probes are located on the guide adapting member in a manner configured to be movable along the second surface of the guide member and the guide adapting member to generate and receive ultrasonic waves used to inspect the component.

The apparatus may further include a processing unit, which may be utilized to at least visualise and process the ultrasonic waves received by the scanning probes.

In one embodiment of the present disclosure, the guide adapting member may be a flexible steel rail arrangement that is bendably and releasably attachable to the guide member depending upon the shape thereof. In one embodiment, the guide member may be a water-cut mask made from one of a rubber, plastic, wood or metal. In one embodiment, a shape of the second surface of the guide member may be adaptable to a surface shape of a portion of the component to render positioning of the scanning probes to enable the ultrasonic waves to appropriately approach the component. In one form, the scanning probes are positioned such that the ultrasonic waves from the scanning probes approach the component radially to the surface of the component.

In another aspect of the present disclosure, a method for ultrasonic inspection of a component is disclosed. The method includes selecting a guide member as per a shape of a portion of the component to be inspected. The guide member is same as summarized above. The selected guide member from its second surface is releasably attached to a guide adapting member. The guide adapting member is the same as summarized above, and includes scanning probes, similar to that summarized above. Thereafter, the guide member, releasably attached to the guide adapting member, is directed onto a surface of the component, whereat the scanning probes generate and receive ultrasonic waves based on the shape of the component.

The method may further include at least visualizing and processing of the received ultrasonic waves from the scanning probes.

In one embodiment, generating and receiving ultrasonic waves include adapting a shape of the second surface the guide member to a surface shape of a portion of the component to render positioning of the scanning probes to enable the ultrasonic waves to appropriately approach the component. In one form, the ultrasonic waves from the scanning probes may radially approach the component to the surface of the component.

These together with the other aspects of the present disclosure, along with the various features of novelty that characterize the present disclosure, are pointed out with particularity in the present disclosure. For a better understanding of the present disclosure, its operating advantages, and its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION

For a thorough understanding of the present disclosure, reference is to be made to the following detailed description, including the appended claims, in connection with the above described drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, structures and apparatuses are shown in block diagrams form only, in order to avoid obscuring the disclosure. Reference in this specification to “one embodiment,” “an embodiment,” “another embodiment,” “various embodiments,” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but may not be of other embodiment's requirement.

Although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to these details are within the scope of the present disclosure. Similarly, although many of the features of the present disclosure are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present disclosure is set forth without any loss of generality to, and without imposing limitations upon, the present disclosure. Further, the relative terms, such as “first,” “second,” and the like, herein do not denote any order, elevation or importance, but rather are used to distinguish one element from another. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

Referring now toFIGS. 1 and 2, examples of a component inspection apparatus100(hereinafter ‘apparatus100’) for an ultrasonic inspection of a component ‘C,’ (shown inFIGS. 3A and 3B), are illustrated in accordance with an exemplary embodiment of the present disclosure.FIG. 1illustrates an assembled view whereasFIG. 2illustrates an exploded view of the apparatus100. In as much as the construction and arrangement of the apparatus100, various associated elements may be well-known to those skilled in the art, it is not deemed necessary for purposes of acquiring an understanding of the present disclosure that there be recited herein all of the constructional details and explanation thereof. Rather, it is deemed sufficient to simply note that as shown inFIGS. 1 and 2, in the apparatus100, only those components are shown that are relevant for the description of various embodiments of the present disclosure.

The apparatus100includes a guide member110, a guide adapting member120and scanning probes122in a configuration. The guide member110includes a first surface112and a second surface114distal from the first surface112. Particularly, the first and second surfaces112,114are opposite to each other. The first surface112is designed in a manner to adaptably mirror a shape of a portion of the component C to be inspected. The second surface114has distal ends with a length therebetween. In one embodiment, the guide member110may be a water-cut mask made from one of rubber, plastic or metal. However, without departing from the scope of the present disclosure, the guide member110may be made from any other material, such as wood, partial board, etc., by using suitable techniques. Such guide member110is configured to the guide adapting member120. Specifically, the guide adapting member120is adapted to be releasably attaching the guide member110from the second surface114of the guide member110by releasable attachments130in such a way that during testing the guide adapting member120and the guide member110do not move relative to each other. This is one a salient feature of the apparatus100that the guide member110is adaptably changeable as per the shape of the portion of the component C, to be releasably attached over the guide adapting member120via the releasable attachments130. Examples of such releasable attachments130may be snap fit attachments, riveted attachments, nut-bolt attachments, and the like.

In one embodiment of the present disclosure, the guide adapting member120may be a flexible steel rail arrangement that is bendable so as to adapt a shape of the second surface114of the guide member110and be releasably attached the guide member110independent upon the shape of the guide member110. That is, the guiding adapting member120by being flexible is capable of being releasably attached to guide members110of different shapes. Without departing from the scope of the present disclosure, the guide adapting member120may be made of any suitable material having required flexibility and bendability to adapt the shape of the second surface114of the guide member110and to releasably attach the guide member110.

The scanning probes122may be located on the guide adapting member120for being configured to be movable along the second surface114of the guide member110to generate and receive ultrasonic waves used to inspect the component C. In one embodiment of the present disclosure, the scanning probes122may be phased array scanning probes, which allow beam steer and skew, i.e. the beam can be steered in two planes. Using such phased array scanning probes, an area or portion which can be inspected from a specific position of the component C may be increased.

In an example, such phased array scanning probes may be moveably positioned along the second surface114on the guide member110, between the guide member110and the guide adapting member120, and may be coupled to a coupler placed proximate to the first surface112of the guide member110to transmit and receive ultrasonic waves towards and from the second surface114for inspection of the portion of the component C. The shape of the second surface114of the guide member110is adaptable to the surface shape of the portion of the component C to render positioning of the scanning probes122to enable the ultrasonic waves to appropriately approach the components C, if required by such coupler. In an example, the scanning probes122may be positioned such that the ultrasonic waves from the scanning probes122radially approach the component C to the surface of the component C.

The apparatus100may include a processing unit for at least visualizing and processing the received ultrasonic waves from the scanning probes122for analyzing flaws, such as crakes in the component C.

Referring now toFIGS. 3A and 3B, which illustrate ultrasonic inspection of the component C, such as low pressure last stage steam turbine blades, using the apparatus100. InFIG. 3A, the guide member110as per the shape of the portion the component C is selected, and is releasably attached to the guide adapting member120by the releasable attachment130for configuring the apparatus100as shown inFIG. 3Bto inspect the component C.

The apparatus100may be placed between the turbine blades such that the second surface114of the guide member110faces that turbine blade which is to be inspected. The guide member110is designed, specifically the second surface114thereof, to adaptably mirror, i.e. to match the shape of the portion of the turbine blade. Since, the turbine blades are of varying profile, the apparatus100may be modified to adapt to any varying size, shape and geometry of the turbine blade to be inspected, by changing the guide member110as per the turbine blade profile or the portion of the turbine blade from the guide adapting member120to obtain the apparatus, such as the apparatus100, suitable of a specific turbine blade or a portion of the turbine blade. Upon matching of the profile of the guide member110with the turbine blade profile, the scanning probes122, which is movable along the second surface114of the guide member110generate and receive ultrasonic waves for scanning the turbine blades. The apparatus100may be inserted between the turbine blades even in case of blades mounted inside the turbine, as specifically shown inFIG. 3B.

Referring now toFIG. 4, a flow diagram of a method200for an ultrasonic inspection of a component C, like low pressure last stage steam turbine blades, is illustrated, in accordance with exemplary embodiment of the present disclosure. The method200, at210, includes a selection of a guide member110, such as the guide member110, as described above, as per the shape of a portion of the component C. In one embodiment of the present disclosure, selection of the guide member110may be made randomly by matching various guide members110with the shape of the component C that is to be inspected, to determine a suitable guide member110that mirrors the component C. However, without departing from the scope of the present disclosure, the selection of the suitable profile of the guide member110as per the shape of the component C may be made by any other technique.

Further, at220, the selected guide member is releasably attached to a guide adapting member by releasable attachments, such as the releasable attachments130as described above. The guide adapting member is same (guide adapting member120) as described above, and includes scanning probes, similar to the scanning probes122. Thereafter at230, the guide member, which is releasably attached to the guide adapting member, is directed on the surface of the component C, and enabling the scanning probes, at240, to generate and receive ultrasonic waves for inspection of the component C.

The apparatus and the method for an ultrasonic inspection of the components of the present disclosure are advantageous in various scopes. The apparatus and method of the disclosure are adaptable in terms of being modified for ultrasonic inspection of a component, like low pressure last stage steam turbine blades of varying shapes, size and geometries. Specifically, the guide member110is changeable per the shape of the component C to be releasably attached over the guide adapting member120. Further, the apparatus and method are convenient to use and economical. Various other advantages and features of the present disclosure are apparent from the above detailed description and appendage claims.