Post on 07-Aug-2015
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MONITORING CAPABILITY OF THE TAM PANELL FOR SYSTEM PERFORMANCE VERIFICATION
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• ASTM E1417-11ε1
• PRIME SPECIFICATION THAT FORESEEN THE SYSTEM PERFORMANCE
VERIFICATION THROUGH TAM PANEL PSM-5, AS:
• GE Aviation:P3TF2/P3TF47 – Rolls Royce: RPS702/EIS1169 –
Pratt&Whitney:FPM MASTER - SNECMA/SAFRAN: DMC0010 – MTU: MTV
1030 – Honeywell: 52309 - Aviogroup: 9300F – Agusta
Westland:AWPS006X
REFERENCE SPECIFICATION
Premises
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• In the “Top 5 Checklist Findings for 2011 “- AC7114/1 the first 4 places include topics relevant to the System Performance Verification or to the control of the TAM Panel
• TAMs, became “reference standard”, especially in the aerospace, but nevertheless few test have been performed to document their capability to realize actually what the specification expect by them.
• The purpose has always been to establish the "BASELINE" conditions of the know defect standard casting - that is the initial condition of the Performance of the Penetrant System , to be compared daily in monitoring the System.
RELEVANT ISSUES
Premises
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(Penetrant System Monitoring – 5 indications)
“STARBUST”TAM (Testing And Monitoring)
A B C D E
TAM PSM-5
Manufactured on the basis of the original P&W drawing
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Identification of the Starbust A B C D E
Dimensional range (mm.) 0.38 ÷ 0.79 1.17 ÷ 1.57 1.91 ÷ 2.36 3.18 ÷ 4.34 4.57 ÷ 6.35
Drawing & Dimensions from Pratt&Whitney 146040
TAM PSM-5
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TYPE OF TAM PANEL
• TAM 146040-1: It shows chrome-plated surfaces and mirror polished in the area where the artificial defects are placed.
• TAM 146040-2: It shows everywhere sandblasted surfaces
TAM PSM-5
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Sensitivity level of the Penetrant
Minimum number of surface indications
Classificationof the defectsto be found
2 3 C,D,E3 4 B,C,D,E4 5 A,B,C,D,E
BASELINE PROCESS• Minimum number of TAM panel defects visible
during PT
TAM PSM-5
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BASELINE PROCESSTAM PSM-5
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S/N 28220
970P25E
S/N 33995
S/N 31334
RC 77
S/N 31335
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• Document the "real" capability of these tools in 'carrying out the daily System Performance Verification for which they are employed.
• Determine the effectiveness of these known defect standards by checking if they are able to discriminate deviations exceeding the limits of the specification, even very slight, connected to the control of the penetrant process.
TARGET of the TEST
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a) Chemical contamination of the penetrant and of the emulsifier
Performed tests
b) Temperature variations of the penetrant
c)Variation of penetrant and developer dwell time
Check influences on the process control through:
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POLLUTANTS
TEST PARAMETERS
Pressure Time Temperature
Performed Tests
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Sherwin Hydrofilic Emulsifier ER83A
Ardrox WW Penetrant 970P25E
Type 1 Method A Level 3
Sherwin PE PenetrantRC 77
Type 1 Method D Level 4
Sodium Hydroxyde (2-5-7-
10 % v/v)
Nitric Acid (2-5-7-10 % v/v)
Water(5-10-15-20 % v/v)
Ardrox WW Penetrant HM430
Type 1 Method A Level 3
Turco 4215 NC-LT
(30 % v/v)
Pollutants
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Test identification
S/N 28220
Detailsof test
parameters
S/N 33995
Green square highlights a substantial invariance of the performance of the
TAM respect to the BASELINE
S/N 28220
Detailsof test
parameters
S/N 33995
Red square highlights a substantial variance of the performance of the TAM respect to the BASELINE
Name Product – Test Parameters
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Pollutants
S/N 28220
5%
S/N 33995
S/N 28220
10%
S/N 33995
ARDROX 970P25 – H2O (5-10 %v/v)
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Pollutants
S/N 28220
15%
S/N 33995
S/N 28220
20%
S/N 33995
ARDROX 970P25 – H2O (15-20 %v/v)
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Pollutants
S/N 31334
5%
S/N 31335
S/N 31334
10%
S/N 31335
SHERWIN RC77 – H2O (5-10 %v/v)
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Pollutants
S/N 31334
15%
S/N 31335
S/N 31334
20%
S/N 31335
SHERWIN RC77 – H2O (15-20 %v/v)
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S/N 28220
2%
S/N 33995
S/N 28220
5%
S/N 33995
ARDROX 970P25 – HNO3 (2-5 %v/v)
Pollutants
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Pollutants
S/N 28220
7%
S/N 33995
S/N 28220
10%
S/N 33995
ARDROX 970P25 – HNO3 (7-10 %v/v)
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Pollutants
S/N 31334
2%
S/N 31335
S/N 31334
5%
S/N 31335
SHERWIN RC77 – HNO3 (2-5 %v/v)
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Pollutants
S/N 31334
2%
S/N 31335
S/N 31334
5%
S/N 31335
SHERWIN RC77 – NaOH (2-5 %v/v)
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Pollutants
S/N 31334
7%
S/N 31335
S/N 31334
10%
S/N 31335
SHERWIN RC77 – NaOH (7-10 %v/v)
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Pollutants
S/N 28220
2%
S/N 33995
S/N 28220
5%
S/N 33995
ARDROX 970P25 – NaOH (2-5 %v/v)
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Pollutants
S/N 28220
7%
S/N 33995
S/N 28220
10%
S/N 33995
ARDROX 970P25 – NaOH (7-10 %v/v)
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Pollutants
S/N 31334
2%
S/N 31335
S/N 31334
5%
S/N 31335
SHERWIN ER83A – NaOH (2-5 %v/v)
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Pollutants
S/N 31334
7%
S/N 31335
S/N 31334
10%
S/N 31335
SHERWIN ER83A – NaOH (7-10 %v/v)
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Pollutants
S/N 31334
10%S/N
31335
SHERWIN ER83A – HNO3 ( 10%v/v)
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Pollutants
S/N 31334
20%S/N
31335
SHERWIN ER83A – H2O ( 20%v/v)
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SHERWIN HM430 – TURCO 4215 NC-LT (30 %v/v)
Pollutants
S/N 28971
30%S/N
28218
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Water pressure
Ardrox WW Penetrant 970P25E
Type 1 Method A Lev 3
Sherwin PE PenetrantRC 77
Type 1 Method D Lev 4
Washing pressure
50-300 kPa
ARDROX 970P25 50-300 kPa
TEST PARAMETERS :
WATER PRESSURE
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S/N 31334
50 kPa
S/N 31335
S/N 31334
300kPa
S/N 31335
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S/N 31334
50 kPa
S/N 31335
S/N 31334
300 kPa
S/N 31335
SHERWIN RC77 50-300 kPa
TEST PARAMETERS :
WATER PRESSURE
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Time
Ardrox WW Penetrant HM430
Type 1 Method A Level 3
Dwell time with liquid penetrant
Developping time(4-10-30-60 min.)
Immersion
(min.)
Draining
(min.)
0 0
2 2
5 5
1 15
60 60
34S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430Immersion 1 sec. – Draining 1 sec.
TEST PARAMETERS:
PENETRANT DWELL TIME
35S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430Immersion 2 min. – Draining 2 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
36S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430Immersion 5 min. – Draining 5 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
37S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430Immersion 1 min. – Draining 15 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
38S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430Immersion 60 min. – Draining 60 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
39S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 4 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
40S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 10 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
41S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 30 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
42S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 60 min.
TEST PARAMETERS:
PENETRANT DWELL TIME
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Temperature
Ardrox WW Penetrant HM430
Type 1 Method A Level 3
PenetrantTemperature
(5°-50°-80 °C)
Ardrox WW Penetrant 970P25E
Type 1 Method A Level 3
Sherwin PE PenetrantRC 77
Type 1 Method D Level 4
Drying Temperature(100-120 °C)
Washing Temperature (5°-50°-80 °C)
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SHERWIN HM430 5 °C
TEST PARAMETERS:PENETRANT
TEMPERATURE
S/N 28971
5°CS/N
28218
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SHERWIN HM430 50 °C
S/N 28971
50°CS/N
28218
TEST PARAMETERS:PENETRANT
TEMPERATURE
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SHERWIN HM430 80 °C
S/N 28971
80°CS/N
28218
TEST PARAMETERS:PENETRANT
TEMPERATURE
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S/N 28220
5 °CS/N
33995
S/N 31334
S/N 31335
ARDROX 970P25 - SHERWIN RC77 5 °C
TEST PARAMETER:
WASHING REMPERATURE
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S/N 28220
50 °CS/N
33995
S/N 31334
S/N 31335
ARDROX 970P25 - SHERWIN RC77 50 °C
TEST PARAMETER:
WASHING REMPERATURE
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S/N 28220
80 °CS/N
33995
S/N 31334
S/N 31335
ARDROX 970P25 - SHERWIN RC77 80 °C
TEST PARAMETER:
WASHING REMPERATURE
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S/N 28220
100°C
S/N 33995
S/N 28220
120°C
S/N 33995
ARDROX 970P25 100-120 °C
TEST PARAMETERS:
DRYING TEMPERATURE
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S/N 31334
100 °C
S/N 31335
S/N 31334
120 °C
S/N 31335
SHERWIN RC77 100-120 °C
TEST PARAMETERS:
DRYING TEMPERATURE
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Temperature &
Time
Drying Temperature(25°-80 °C)
Ardrox WW Penetrant 970P25E
Type 1 Method A Level 3
Sherwin PE PenetrantRC 77
Type 1 Method D Level 4
Drying Time(30-60 min.)
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S/N 28220
25 °C
S/N 33995
S/N 28220
80 °C
S/N 33995
ARDROX 970P25 25°- 80 °C 15 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI OF DRYING
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S/N 31334
25 °C
S/N 31335
S/N 31334
80 °C
S/N 31335
SHERWIN RC77 25°- 80 °C 15 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI OF DRYING
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S/N 31334
30 min.
S/N 31335
S/N 31334
60 min.
S/N 31335
SHERWIN RC77 65 °C 30-60 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI OF DRYING
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S/N 28220
30 min.
S/N 33995
S/N 28220
60 min.
S/N 33995
ARDROX 970P25 65 °C 30-60 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI OF DRYING
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Conclusions (1)
The addition of sodium hydroxide does not show significant effects about the process monitoring at all tested concentrations
The presence of water, causes a progressive attenuation of the intensity of the indications and a degradation of their size - At levels of 15 -20% only parts of the two discontinuities of greater dimensions (D – E) are still visible
Alkaline degreasers in aqueous solution such as the TURCO 4215 NC-LT not seem to have impact on the effectiveness of the Penetrant System
Pollutants in the emulsifier, used for high sensitivity penetrant cause no tangible effects - only nitric acid causes valuable changes!
The presence of nitric acid , progressively eliminates the brightness of the penetrant, which remains almost unchanged up to a concentration of 2% (v / v)
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Conclusions (2)
Increasing the temperature in the oven drying occurs a progressive deterioration of the sharpness of the indications accompanied by the deposition of fluorescent pigment from the temperature of 100 ° C. The dwell time of greatest impact on water washable reducing penetrant brightness and sharpness of starbusts
The obtained results appear to be insensitive to changes in penetrant dwell time (immersion and draining), ranging from a few seconds up to one hour and to variations in the application temperature from 5 ° C to 80 ° C!
Increasing the pressure of the water washing a small attenuation of the brightness of the individual indications has been observed, but no dramatic evidence appear even up to 300 kPa
The variation of washing temperatures (operation, typically performed in the range 10 ° to 38 ° C) is not detected during System Performance effectiveness. After a washing at 80 ° C It is still valuable the starbust A
Conclusions (3)
WHAT IS APPEARING FROM THE OBTAINED RESULTS:
1) The TAM PANEL 146040 showed some limits relevant to the possible drift of the penetrant process.
2) Therefore, there is the possibility to have working conditions do not conform to the applicable requirements ….
BUT……………. 3) What can happen instead on the actual defects in the inspected
components? 4) And 'the magic halo attributed to this instrument which is delegated
to the effective Performance Effectiveness Verification of the system is justified?
The evidence of the monitoring do not seem to be affected by the percentage of dwell time - immersion respect to that of drainage
The tests reveal no variations due to different development time used, at least in the range tested.
Conclusions (4)
After all these consideration about the TAM146040 effectiveness,what do we have to consider about the its supply condition?
For a good daily practice, it is mandatory the initial fulfillment of 146040 drawing requirements , about the 5 starbusts size ?
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Special Thanks / Credits
Thanks to the article of George Hopman published on “Material Evaluation” - February 2009 …It has given us an opportunity to deepening the concept concerning an subject that raised so many issues during the audit
A special thanks to a couple of colleagues:
A.Martignetti and G. Petronella – Alenia Aermacchi who have shared and contributed to the development of these subjects.
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Question time
? ??