Patent Description:
The anomalies can result in degraded performance or even inoperability of a component. Therefore, detection capabilities of such anomalies are important. In instances where the anomalies mentioned earlier, especially RX, occur in the interior of the component or on a region which is covered by a coating, the detection of the anomalies by nondestructive techniques (with respect to the component) is not possible with conventional technology.

<CIT> and <CIT> disclose features of the preamble of claim <NUM>.

<CIT> discloses a method and apparatus for monitoring the interface between crystalline solid and amorphous liquid phases in a mold.

Aspects of the invention are directed to a method for analyzing a material of a component, as claimed in claim <NUM>. In some embodiments, the component is associated with an engine of an aircraft. In some embodiments, the component includes a turbine blade. In some embodiments, the reference beam pattern is expected to be emanated by the component when the component is subject to the radiation. In some embodiments, the component is associated with a semiconductor. In some embodiments, the component has a coating. In some embodiments, the radiation comprises x-ray radiation. In accordance with the invention, the method further comprises specifying the anomaly in terms of at least one of: a crystalline orientation of the material, a location of the anomaly, and a size of the anomaly. In some embodiments, the method further comprises rejecting the component when the deviation is greater than a threshold. In some embodiments, the method further comprises repairing the component when the deviation is greater than a threshold.

Aspects of the invention are directed to a system for analyzing a material of a component, as claimed in claim <NUM>. In some embodiments, the x-ray radiation has an energy within a range of 40KeV - 600KeV. In some embodiments, the system comprises a collimation system configured to control a size of the input radiation to within a range of <NUM> - <NUM>. In some embodiments, the system further comprises a sample stage configured to load a plurality of components, the plurality of components including the component. In some embodiments, the control computer is configured to issue a command to the sample stage to orient the component with respect to at least one of the source or the detector. In some embodiments, the command directs the sample stage to orient the component in terms of at least one of a distance or an angle with respect to the at least one of the source or the detector. In some embodiments, the sample stage has between one and six axes of mobility. The at least one of the control computer or the detector is configured to specify the anomaly in terms of at least one of: a crystalline orientation of the material, a location of the anomaly, and a size of the anomaly.

It is noted that various connections are set forth between elements in the following description and in the drawings It is noted that these connections are general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. A coupling between two or more entities may refer to a direct connection or an indirect connection. An indirect connection may incorporate one or more intervening entities.

In accordance with various aspects of the disclosure, apparatuses, systems, and methods are described for non-destructively detecting crystalline domains having an orientation that differs from a matrix in a nominally single-crystal (SX) component/structure by use of high energy X-rays. An RX defect can be detected based on measured orientation difference between the area with defect and adjacent defect free area using one or more thresholds. For example, in some embodiments the techniques that are described herein may be applied to volumes that are based on or defined by computational modeling, where the computational modeling may serve as a basis for the thresholds. Still further, in some embodiments a "coupon" or other portion or segment that is characteristic of the volume may be evaluated or serve as a baseline for establishing a reference specification or model.

Aspects of the disclosure may be used to ensure that grains of material stay on-axis, which may assist in promoting strength/toughness and creep resistance. Additionally, aspects of the disclosure may provide for a determination of mal-oriented grains (MOG), in a nondestructive manner. In some embodiments, a determination may be made whether MOG due to recrystallization has occurred during production or when a component has been placed into service.

In some embodiments, a controlled size X-ray beam may be transmitted and directed toward and through a component and diffraction data may be obtained based on the transmitted X-ray. A mapping of the diffraction data, potentially based on one or more reference specification or models, may be obtained to determine if a crystalline orientation associated with the component differs from a specification in an amount that exceeds one or more thresholds.

In some embodiments, diffraction data may be analyzed to determine if a single of multiple grains exist in interrogated volumes.

In some embodiments, a scanning or mapping of an x-ray beam may be provided throughout the entirety or a portion of a component to assess each incremental volume for single or multiple grain appearance.

In some embodiments, computational models of solidification processes and/or heat treatments may be used to determine volumes exposed to a risk of recrystallization, where the risk may be based on the use of one or more thresholds.

In some embodiments, computational models and X-ray characterizations of nominally SX materials or components may be determined/obtained. Such features may be used to enhance the rate or probability of detecting secondary grains.

Aspects of the disclosure may be applied in connection with one or more components of a gas turbine engine. <FIG> is a side cutaway illustration of a geared turbine engine <NUM>. The turbine engine <NUM> extends along an axial centerline <NUM> between an upstream airflow inlet <NUM> and a downstream airflow exhaust <NUM>. The turbine engine <NUM> includes a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM> and a turbine section <NUM>. The compressor section <NUM> includes a low pressure compressor (LPC) section 19A and a high pressure compressor (HPC) section 19B. The turbine section <NUM> includes a high pressure turbine (HPT) section 21A and a low pressure turbine (LPT) section 21B.

The engine sections <NUM>-<NUM> are arranged sequentially along the centerline <NUM> within an engine housing <NUM>. Each of the engine sections <NUM>-19B, 21A and 21B includes a respective rotor <NUM>-<NUM>. Each of these rotors <NUM>-<NUM> includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).

The fan rotor <NUM> is connected to a gear train <NUM>, for example, through a fan shaft <NUM>. The gear train <NUM> and the LPC rotor <NUM> are connected to and driven by the LPT rotor <NUM> through a low speed shaft <NUM>. The HPC rotor <NUM> is connected to and driven by the HPT rotor <NUM> through a high speed shaft <NUM>. The shafts <NUM>-<NUM> are rotatably supported by a plurality of bearings <NUM>; e.g., rolling element and/or thrust bearings. Each of these bearings <NUM> is connected to the engine housing <NUM> by at least one stationary structure such as, for example, an annular support strut.

During operation, air enters the turbine engine <NUM> through the airflow inlet <NUM>, and is directed through the fan section <NUM> and into a core gas path <NUM> and a bypass gas path <NUM>. The air within the core gas path <NUM> may be referred to as "core air". The air within the bypass gas path <NUM> may be referred to as "bypass air". The core air is directed through the engine sections <NUM>-<NUM>, and exits the turbine engine <NUM> through the airflow exhaust <NUM> to provide forward engine thrust. Within the combustor section <NUM>, fuel is injected into a combustion chamber <NUM> and mixed with compressed core air. This fuel-core air mixture is ignited to power the turbine engine <NUM>. The bypass air is directed through the bypass gas path <NUM> and out of the turbine engine <NUM> through a bypass nozzle <NUM> to provide additional forward engine thrust. This additional forward engine thrust may account for a majority (e.g., more than <NUM> percent) of total engine thrust. Alternatively, at least some of the bypass air may be directed out of the turbine engine <NUM> through a thrust reverser to provide reverse engine thrust.

<FIG> represents one possible configuration for an engine <NUM>. Aspects of the disclosure may be applied in connection with other environments, including additional configurations for an engine of an aircraft.

Aspects of the disclosure may be used to detect crystallographic anomalies in one or more components, such as for example a component of an engine. For example, aspects of the disclosure may be used to detect anomalies in SX blades of the engine <NUM>. The detection may be based on a use of one or more of: (<NUM>) process modeling tools, (<NUM>) a system for diffraction data collection, (<NUM>) logic configured to align components in the diffraction system, (<NUM>) logic configured to obtain and analyze data, and (<NUM>) logic configured to determine whether an anomaly exists in an amount greater than a threshold.

Referring to <FIG>, an illustrative computing environment <NUM> is shown. The system <NUM> may include one or more processors (generally shown by a processor <NUM>) and a memory <NUM>. The memory <NUM> may store data <NUM> and/or instructions <NUM>. The system <NUM> may include a computer-readable medium (CRM) <NUM> that may store some or all of the instructions <NUM>. The CRM <NUM> may include a transitory and/or non-transitory computer-readable medium.

The data <NUM> include one or more parameters that may be associated with a component (e.g., a blade). These parameters are based on an actual component that is undergoing analysis or a reference component/specification as is described further below. The parameters are used to determine/detect a crystalline orientation associated with the component and determine/detect whether that orientation differs from the reference specification in an amount greater than a threshold.

The instructions <NUM>, when executed by the processor <NUM>, cause the system <NUM> to perform one or more methodological acts or processes, such as those described herein. Execution of the instructions <NUM> causes the system <NUM> to determine/detect a crystalline orientation associated with a component and determine/detect whether that orientation differs from a specification in an amount greater than a threshold.

Referring now to <FIG>, a system <NUM> in accordance with aspects of the disclosure is shown. The system <NUM> is used to detect a crystalline orientation associated with a component and detect whether that orientation differs from a specification in an amount greater than a threshold.

The system <NUM> includes a source <NUM>. The source <NUM> generates and transmits one or more forms of radiation, such as for example neutron, gamma rays, or x-ray, hereinafter input radiation <NUM>. In some non-limiting embodiments, the input radiation <NUM> may have an associated energy in the range of <NUM>-600KeV. The energy of the source <NUM> may be selected to ensure that signals/beams of sufficiently high quality (e.g., sufficiently high signal-to-noise ratio) are obtained by a detector <NUM>. In some embodiments, the detector <NUM> may be configured as one or more area detector arrays.

The source <NUM> may include, or be associated with, a collimation system <NUM>. The collimation system <NUM> may be configured to control the size of the input radiation <NUM>. In some embodiments, the input radiation <NUM> may range in size (e.g., diameter as projected from the source <NUM>) from <NUM> to <NUM>, +/- <NUM>. The particular size, or even wavelength, that is used for the input radiation <NUM> may be a function of the resolution that is needed in a particular application context. For example, aspects of the disclosure may be used to detect anomalies on the order of <NUM> micrometers, and thus the characteristics of the input radiation <NUM> (e.g., power, size, wavelength, frequency, etc.) may be selected to optimize detections of this order.

While the collimation system <NUM> is shown in <FIG> as being included in the source <NUM>, in some embodiments the collimation system <NUM> may be a separate device relative to the source <NUM>.

The input radiation <NUM> impinges on/interfaces to one or more components, such as for example components 322a, 322b, and 322c. In some embodiments, one or more of the components 322a-322c may include a blade. The components 322a-322c may be associated with a sample stage (denoted as reference character <NUM> in <FIG>). The sample stage <NUM> may include one or more axes of mobility, such as for example one to six axes of mobility. The selection, configuration, or orientation of the axes may be used for providing a particular alignment of the components 322a, 322b, or 322c, may be used to enable a three-dimensional analysis of the components 322a-322c, may be used to examine a particular surface/face of one or more of the components 322a-322c, etc. The sample stage <NUM> may include slots for the components 322a-322c to be loaded into. As part of the loading, the components 322a-322c may be aligned, e.g., on a collective or individual basis.

The operations (e.g., a loading or movement) associated with the sample stage <NUM> are controlled by a computing platform/control computer <NUM>. The sample stage <NUM> and/or the control computer <NUM> include the devices shown and described above in connection with <FIG>.

The control computer <NUM> issues commands to the sample stage <NUM> to control the sample stage <NUM>. The control computer <NUM> and the sample stage <NUM> are communicatively coupled to one another to facilitate the transmission of the commands. The communication may adhere to one or more techniques, protocols, standards, etc. The communication may be wired and/or wireless. In some embodiments, feedback regarding the operations performed by the sample stage <NUM> may be transmitted from the sample stage <NUM> to the control computer <NUM>, which may be used to facilitate closed-loop communication between the sample stage <NUM> and the control computer <NUM>.

In <FIG>, the component 322b is shown as being aligned with the input radiation <NUM>, such that data associated with the component 322b is obtained by a detector <NUM>. The data is based on one or more beams emanating from the component 322b. For example, the data may be based on a transmitted beam <NUM> and one or more diffracted beams <NUM>. The detector <NUM> may be mounted on a device that enables a change in distance between the detector <NUM> and the components 322a-322c and a change in angle between the transmitted beam <NUM> and the normal to the detector <NUM>. In some embodiments, the detector <NUM> may be configured to move and/or the sample stage <NUM> may be configured to move to alter the distance and/or angle as described above. Referring to <FIG>, when the input radiation <NUM> is projected incident to the component 322b, a resulting pattern of the transmitted beam <NUM> and/or the diffracted beams <NUM> is obtained, with the pattern being detected by the detector <NUM> and being the basis for the collected data. The pattern may pertain to a surface and/or volume of the component that is being analyzed (illustratively, the component 322b in <FIG>).

The data obtained via the beam <NUM> and/or the beam(s) <NUM> are compared by the detector <NUM> and/or the control computer <NUM> with a reference specification or model beam pattern to determine/detect a crystalline orientation associated with the component 322b and determine/detect whether that orientation differs from the reference specification/model beam pattern in an amount greater than a threshold. For example, if the component 322b was nominally manufactured/fabricated of a SX material (e.g., a nickel-based material), the potential presence of at least one other crystal/grain in the component 322b as the component 322b was actually manufactured may result in a deviation in the beam <NUM> and/or the beam(s) <NUM> emanating from the component 322b. Thus, the pattern detected by the detector <NUM> may vary from the reference specification or model beam pattern.

A deviation in the actual pattern from the reference pattern in an amount less than a first threshold (e.g., a low angle deviation) may be indicative of low stress, such that the component may be acceptable for use. A deviation in the actual pattern from the reference pattern in an amount greater than a second threshold (e.g., a high angle deviation) may be indicative of a component that is unacceptable for use. The first and second thresholds in this example may be the same.

This deviation in the beam <NUM> and/or the beam(s) <NUM> is used to determine/detect that an anomaly exists in the crystalline orientation of the component 322b. Still further, the deviation is quantified in terms of, e.g., size and location of the anomaly to determine exactly what the crystalline structure and orientation of the component 322b is. Such information may be used to determine how much stress may exist at the crystal/grain-boundaries. As described above, if the stress is less than a threshold, the component 322b may be accepted for use. On the other hand, if the stress exceeds a threshold, the component 322b may be discarded, repaired, or subject to some other action.

While the examples described above related to an assessment of the component 322b in terms of how it was manufactured/fabricated, aspects of the disclosure may be applied to components that are already in-service or in-the-field.

Such in-service components may have materials added to them beyond the SX material that the component is constructed of. For example, aircraft engine components may be subjected to one or more coatings (e.g., a ceramic coating), potentially as part of a thermal barrier coating (TBC) procedure, before they are deployed on the engine. The system <NUM> may be used in conjunction with such components as well; any modifications that are needed might only need to be made with respect to the reference specifications/models that are used for the component to account for the presence of the additional materials/coatings that are included.

Still further, the SX-material of an in-service component may undergo a material change/transformation over time. Such a transformation may be at least partially based on exposure of the component to environmental conditions (e.g., temperature, vibration, etc.). Accordingly, the system <NUM> may be used to determine/detect a modification to the component crystalline orientation or material. If the component is subject to analysis by the system <NUM> over time, changes may be recorded over that same time period. Such information may be analyzed to determine the useful/operative lifetime of the component.

Referring now to <FIG>, a flowchart of an exemplary method <NUM> is shown. The method <NUM> is executed by the sample stage <NUM> and the control computer <NUM> of the system <NUM> to analyze one or more components (e.g., components 322a-322c).

In block <NUM>, one or more models of a component are obtained. A model includes a reference specification of a beam pattern (e.g., a first beam pattern) that is expected to emanate from the component when the component is subjected to a stimulus or input radiation (e.g., x-rays). The reference specification/model may be based on a profile/dimension of the component, an indication of one or more materials that were used in fabricating/manufacturing the component (inclusive of any coatings that may be applied to the component), a profile of a radiation source that is used, or other factors.

In block <NUM>, a component is inserted into the system for analysis. For example, a component may be seated/aligned in the sample stage <NUM>.

In block <NUM>, a source is activated to transmit radiation (e.g., x-rays) towards the component.

In block <NUM>, a beam pattern (e.g., a second beam pattern) that includes one or more beams emanating from the component (based on the radiation transmitted in block <NUM>) is obtained by a detector.

In block <NUM>, the second beam pattern obtained as part of block <NUM> is compared with the first beam pattern of the reference specification/model to determine if the second beam pattern deviates from the first beam pattern in an amount greater than a threshold.

If the deviation in block <NUM> is greater than the threshold, an anomaly may exist and the component may be subjected to rejection, repair, or some other activity in block <NUM>, potentially based on the extent or degree of the deviation.

On the other hand, if the deviation in block <NUM> is less than or equal to the threshold the component may be placed into service, or continue to be used in-service, in block <NUM>.

In block <NUM>, a status (e.g., a report) of the analysis performed in connection with blocks <NUM>-<NUM> is provided. For example, a pass (e.g., block <NUM>) or fail (e.g., block <NUM>) status may be generated as part of block <NUM> for the component. Other types of status may be generated and/or recorded as part of block <NUM>.

The method <NUM> is illustrative. In some embodiments, additional blocks or operations that are not shown may be included. , In some embodiments, at least a portion of the method <NUM> may be automated. Such features may be used to process a large number of components, potentially as part of an assembly line. In this respect, the method <NUM> may be executed repeatedly or as part of a larger loop or algorithm for each component that is to be analyzed.

Aspects of the disclosure may be used to detect anomalies in a component. Such anomalies might otherwise go unnoticed without the teachings of this disclosure. For example, aspects of the disclosure may be used to detect anomalies that may exist within the interior of a component without having to decompose/destruct the component and without having to remove any additional materials (e.g., coatings) that may have been intentionally applied to the component. Still further, when an anomaly is detected the degree/extent of the deviation may be quantified to determine any activities/actions that may need to be taken based on the anomaly.

While some of the examples described herein related to components used in connection with an aircraft engine, aspects of the disclosure may be used in other application environments/contexts. For example, aspects of the disclosure may be used to characterize one or more portions of a semiconductor. If the semiconductor is made of a first/primary material (e.g., silicon), aspects of the disclosure may be used to assess the crystalline properties of the first material even in the presence of one or more additional materials (e.g., gallium arsenide).

Claim 1:
A method for analyzing a material of a component, comprising:
activating a radiation source (<NUM>) to transmit radiation (<NUM>) to the component (322a-c);
obtaining a beam pattern based on the component (322a-c) interfering with the radiation (<NUM>);
comparing the beam pattern to a reference beam pattern; and
detecting that an anomaly exists in a crystalline orientation of the component (322a-c), within the interior of the component, when the comparison indicates a deviation between the beam pattern and the reference beam pattern,
the method characterised by:
quantifying the deviation in terms of a size and a location of the anomaly to determine whether a stress at crystal/grain-boundaries of the material is less than or exceeds a threshold,
wherein the beam pattern is obtained having been transmitted through the component (322a-c).