It is important to be able to assess technicians and their ability to reliably detect critical defects without rejecting acceptable parts. To accomplish this, a series of test kits with a variety of acceptable and unacceptable anomalies needs to be available to perform POD studies. The aim of this proposal is threefold. 1)Identify the types and sizes of defects that need to be detected by categorizing them according to: NDT Method, Part Geometry, Defect Geometry, and Material. 2)Modernize the creation of artificial defects by collaborating with Mound Laser & Photonics Center to image cracks and recreate them at varying depths and lengths. We foresee the advantages to POD studies to include: a. Greater control over defect size, shape, and depth variation. Artificial defects will not be limited to straight lines and simple curves but instead can be jagged and multi-depth. b. Artificial defects that are much smaller when compared to EDM notches. c. Artificial defects that have little to no heat affected zone. 3)Choose specific materials, geometries and artificial defects to include in a POD kit for surface defects. Engineering drawings showing the final product(s) will include cost estimates for producing the kits.
Benefit: Commercial benefits include test kits with manufactured defects that are more representative of defects found on in-service aircraft which will provide the opportunity to maximize POD. Additionally, test kits will be designed to overlap NDT methods such that one test kit can be used for multiple inspection disciplines. This will reduce the cost associated with POD studies.
Keywords: Nondestructive, Testing, Kit, Pod, Nas410, Laser, Inspection, Defect
