Abstract: A method, system and article adapted for ultrasonic inspection of the article. The article is disk-shaped and has axially-oriented slots circumferentially spaced from each other at a periphery of the article, with members secured at the periphery of the article such that each member has a retention feature that extends into and engages a corresponding one of the slots so as to secure the members to the slots. Cavities are defined by and between the slots and radially-inward extremities of the retention features within the slots. The inspection method and system entail the use of at least one ultrasonic transducer placed within at least a first of the cavities defined by a first of the slots. The transducer is configured and oriented to perform a diagnostic technique on the article by emitting an ultrasonic signal that intersects an interior surface of a second of the slots immediately adjacent the first slot.

Abstract: A method, system and article adapted for ultrasonic inspection of the article. The article is disk-shaped and has axially-oriented slots circumferentially spaced from each other at a periphery of the article, with members secured at the periphery of the article such that each member has a retention feature that extends into and engages a corresponding one of the slots so as to secure the members to the slots. Cavities are defined by and between the slots and radially-inward extremities of the retention features within the slots. The inspection method and system entail the use of at least one ultrasonic transducer placed within at least a first of the cavities defined by a first of the slots. The transducer is configured and oriented to perform a diagnostic technique on the article by emitting an ultrasonic signal that intersects an interior surface of a second of the slots immediately adjacent the first slot.

Abstract: A process for producing a rotor, the rotor formed thereby, as well as turbines in which such a rotor is installed. The rotor is formed by casting an ingot to have first and second regions formed of different alloys that intermix during casting to define a transition zone therebetween. The ingot is forged to yield a rotor forging that contains axially-aligned first and second alloy regions and a transition zone therebetween. The effects of the transition zone can be mitigated by modeling the transition zone and then off-center machining the forging so that the axis of rotation of the machined monolithic rotor is more centrally located with respect to the transition zone.

Abstract: A method and system for ultrasonically inspecting turbine wheels and other disk-shaped articles having a central opening and multiple secondary openings radially spaced outward from the central opening. At least one ultrasonic transducer is placed in at least one of the secondary openings of the wheel. The transducer is configured and oriented to perform a pulse-echo diagnostic technique on the wheel by emitting ultrasonic signals that intersect radials of the wheel at angles of approximately ninety degrees to the radials. The ultrasonic signals intersect the radials at points so that a plurality of points are located on a plurality of radials. The points define a locus of points through the volume of the wheel between the central opening and the secondary opening, such that the volume is inspected for defects. The transducer receives ultrasonic signals that are reflected from one or more points when a defect is encountered.

Abstract: A method and system for evaluating structural defects in metals is provided. In one embodiment, the method recognizes that the acceptability of a given defect is principally determined by the four basic parameters of operating temperature, operating stress, defect area, and defect shape. Ranges are established for each of these four basic parameters, and intermediate values within these ranges are selected to create a series of index value data sets. The method evaluates these index value data sets by calculating a life cycles estimate for each. Using statistical methods, the life cycles results are analyzed to determine the effect each of the four basic parameters has on the life of a component with a defect. Understanding the relationship between these four basic parameters and life cycles enables the method to provide an interpolation algorithm for finding the life cycles for any component having a defect.

Abstract: A method and system for evaluating structural defects in metals is provided. In one embodiment, the method recognizes that the acceptability of a given defect is principally determined by the four basic parameters of operating temperature, operating stress, defect area, and defect shape. Ranges are established for each of these four basic parameters, and intermediate values within these ranges are selected to create a series of index value data sets. The method evaluates these index value data sets by calculating a life cycles estimate for each. Using statistical methods, the life cycles results are analyzed to determine the effect each of the four basic parameters has on the life of a component with a defect. Understanding the relationship between these four basic parameters and life cycles enables the method to provide an interpolation algorithm for finding the life cycles for any component having a defect.