Appendix 4
(3) Manipulation of the part was possible to present to the inspector an unimpeded view of the surface to be inspected.
b. The default POD data apply to surface-connected low-cycle fatigue cracks. Cracks are assumed to have a 2-to-1 aspect (length:depth) ratio. Crack sizes are expressed in terms of the length at the surface. Cracks must not be obscured by oxide, contaminants, etc. Inspected surfaces should readily visible. Choice of the appropriate POD curve from those provided must be based on whether focused or full field inspection conditions apply, as those terms are defined in paragraph 3 in the main body of the AC.
6. Restrictions and Applicability: Ultrasonic Inspection (UT)
a. UT is an inspection technique suitable for the detection of subsurface anomalies. For the purposes of this document, it is intended for application both to billets and to engine-run components. The default POD data were acquired under the following conditions:
(1) 5 MHz inspection frequency.
(2) Water immersion inspection conditions.
(3) Normal incidence longitudinal wave mode for inspection of billet using single 0.5 inch x 1.0 inch cylindrically focused transducer.
(4) Shear wave mode for inspection of finish-machined components using 0.75 inch diameter spherically focused transducer.
(5) Transducer (search unit) fixturing was capable of following surface contours of the component being inspected, with adequate control of attitude and scan indexing.
(6) Provision was made for automatic recording of the inspection process signals or automated alarm, or both, when the inspection threshold was exceeded.
b. For ultrasonic inspection, the default POD data apply to mixtures of anomalies typical of those that may be found in billet, or in engine-run material, as appropriate. These anomalies include hard-alpha associated voids or cracks, strain induced porosity, A4-4
Appendix 4 etc. It should be noted that other anomaly types may occur, such as high density inclusions, but these are not included in the current analysis. Anomaly sizes are expressed in terms of maximum cross-sectional area perpendicular to the sound beam, including associated diffusion zones where appropriate.
c. Inspected finish-machined surfaces should be flat, or only moderately curved. Billets should be circular-cylindrical, and in customary pre-inspection conditions (turned, ground, or peeled).
d. Choice of the appropriate POD curve from those provided must be based on component demonstration of the attainable inspection sensitivity (see paragraph 2 of this Appendix). Provision must be made to maintain this sensitivity at all depths, and effective distance-amplitude compensation is required.
A4-5
Appendix 5 APPENDIX 5
DEFAULT POD CURVES A5-1
Appendix 5 FIGURE A5-1
POD FOR FLUORESCENT PENETRANT INSPECTION OF
FINISH-MACHINED SURFACES 100 90 80 Percent. POD 70 20 10 10 100 1000 ANOMALY LENGTH (mils) Full-field inspection Applicability:
Directed inspection MIL-I-25135 Level 4 penetrants with dry powder developer (as minim) A5-2
Appendix 5 FIGURE A5-2 MEAN (50% CONFIDENCE) POD FOR ULTRASONIC
INSPECTION OF FIELD COMPONENTS #1 FBH (1/64 INCH DIA.) CALIBRATION 100 90 80 Percent POD 70 40 30 20 100 1000 10000 100000 ANOMALY AREA (mils^2) Billet: data taken with 0.5x1i cylindrically focused transducer Finish-machined part: data taken with 0.75" diameter spherically focused transducer Reject indications equal to or greater than those from a 1/64 in dia FBH
• — Reject indications equal to or greater than one half those from a 1/64 in dia FBH Applicability:
Hard-alpha associated inclusions/ cracks/voids (includes diffusion zones) Billet: 5MHz longitudinal (compressional) wave inspection circular-cylinderical billet Finish-machined: 5MHz shear (transverse) wave inspection applicable only if the indicated sensitivity is attainable A5-3
Appendix 5 FIGURE A5-3 MEAN (50% CONFIDENCE) POD FOR ULTRASONIC
INSPECTION OF FIELD COMPONENTS #2 FBH (2/64 INCH DIA.) CALIBRATION 100 90 80 Percent POD 70 50 30 20 10 100 1000 10000 100000 ANOMALY AREA (mils^2) Billet: data taken with 0.5x1l cylindrically focused transducer Finish-machined part: data taken with 0.75" diameter spherically focused transducer Reject indications equal to or greater than those from a 2/64 in dia FBH
• - Reject indications equal to or greater than one half those from a 2/64 in dia FBH Applicability:
Hard-alpha associated inclusions/ cracks/ voids (includes diffusion zones) Billet: 5MHz longitudinal (compressional) wave inspection circular-cylinderical billet Finish-machined: 5MHz shear (transverse) wave inspection Applicable only if the indicated sensitivity is attainable A5-4
Appendix 5 FIGURE A5-4 MEAN (50% CONFIDENCE) POD FOR ULTRASONIC INSPECTION OF
FIELD COMPONENTS #3 FBH (3/64 INCH DIA.) CALIBRATION 100 90 80 Percent POD 70 30 20 10 100 1000 10000 100000 ANOMALY AREA (mils^2) Billet: data taken with 0.5x1" cylindrically focused transducer Finish-machined part: data taken with 0.75" diameter spherically focused transducer Reject indications equal to or greater than those from a 3/64 in dia FBH
- - Reject indications equal to or greater than one half those from a 3/64 in dia FBH Applicability:
Hard-alpha associated inclusions/ cracks/ voids (includes diffusion zones) Billet: 5MHz longitudinal compressional) wave inspectio ircular-cylinderical bille Finish-machined: 5MHz shear (transverse) wave inspection applicable only if the indicated sensitivity is attainable A5-5
Appendix 5 FIGURE A5-5 MEAN (50% CONFIDENCE) POD FOR EDDY CURRENT OF
FINISH-MACHINED SURFACES 100 90 80 70 Percent POD 60 30 20 10 10 100 ANOMALY LENGTH (mils) Reject at the calibration notch threshold response and above Reject at one half the calibration notch threshold response and above Applicabilty:
Absolute coils, 2-6 MHz inspection frequency Calibration on 0.030" x 0.015" notch applicable only if the indicated sensitivity is attainable A5-6
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