Component Penetrant Testing With Solid Blasting for Automated Detection
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Solution Overview
Problem
Existing penetrant testing methods, particularly in turbomachines, suffer from manual processes that are difficult to automate, leading to inconsistent parameter control and potential washout of penetrant from defect sites, compromising detection accuracy.
Innovation Solution
A method involving the use of a solid blasting material to abrade excess penetrant from the component surface, controlled by pressure and exposure time, combined with robotic application, to differentiate between defect sites and penetrant residues, using a liquid-solid mixture or separate nozzles for targeted removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual mechanical abrasion with brush and solvent is used to remove excess penetrant, then penetrant removal is achieved, but automation is difficult and process parameters cannot be consistently controlled
Solution Approach 1:
The patent replaces manual mechanical abrasion with brush and solvent with a pneumatic system that uses compressed air to blow excess penetrant off the component surface. This substitution enables full automation while maintaining effective penetrant removal, as the air stream can be precisely controlled and directed without requiring manual intervention.
Solution Approach 2:
The invention employs pneumatic principles by using compressed air flow to remove excess penetrant. The system utilizes air pressure and flow rate control to achieve consistent penetrant removal across different components and operating conditions, enabling automated operation with reproducible results.
2Manufacturing precision
If excessive solvent is used to ensure complete penetrant removal, then surface cleaning is improved, but washout from defect sites occurs reducing detection accuracy
Solution Approach 1:
The pneumatic system uses controlled air pressure and flow to remove penetrant selectively. The air stream removes excess penetrant from the surface through aerodynamic forces without requiring large amounts of solvent, thereby preventing washout from defect sites while still achieving adequate surface cleaning for accurate detection.
Solution Approach 2:
The invention changes the removal mechanism from solvent-based chemical action to air-based physical action. By adjusting air pressure and flow rate parameters, the system achieves optimal balance between surface cleaning and preventing defect site washout, improving both surface quality and detection accuracy.
3Adaptability or versatility
If manual abrasion process is used, then penetrant removal is achieved, but process parameters vary greatly depending on test type
Solution Approach 1:
The pneumatic system provides consistent and reproducible penetrant removal through controlled air pressure and flow rate. These parameters can be precisely regulated and maintained constant across different test types, eliminating the variability inherent in manual operations while remaining adaptable to different component geometries and test requirements.
Solution Approach 2:
The system allows dynamic adjustment of air pressure and flow rate parameters to suit different test types and component configurations. This dynamic control capability maintains parameter consistency within each test type while providing versatility across different applications, resolving the contradiction between adaptability and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances reproducibility and automation, preventing washout from small cracks, improving detection accuracy and enabling reliable identification of defects in turbomachine components.
Implementation Method 1
the surface is blasted after the introduction of the penetrant and prior to the optical detection, namely by using a solid blasting material; a rather excessive amount of penetrant, at least proportionally, is then abraded from the component surface
Implementation Method 2
The penetrant is applied into the defect sites, based on capillary forces for example, so that said sites are well visible in a subsequent optical inspection
Data Source
AI summary
The present invention relates to a method for testing a component by a penetrant test, in which a penetrant is introduced onto a surface of the component; at least one portion of the penetrant is removed from the surface by blasting the surface with a solid blasting material; the surface is optically detected after the blasting.