Weld inspection plays a pivotal role in ensuring the integrity and reliability of critical components in industries such as aerospace, defence, and manufacturing. For applications like rocket propellant systems and aircraft parts, welds must meet stringent safety and quality standards. The inspection of titanium welds is particularly vital due to the material’s high corrosion resistance and its use in environments where failure is not an option.

Challenges

The client required the inspection of 110mm thick titanium welds with a narrow groove U configuration. However, several challenges complicated the process:

  1. Material Properties: Titanium’s grain structure led to a poor Signal-to-Noise Ratio (SNR), making flaw detection difficult.
  2. High Sound Attenuation: Similar to stainless steel, titanium exhibits high sound attenuation, which complicates ultrasonic testing.
  3. Inspection Specifications: The inspection needed to detect:
    • Side-drilled holes of 3mm and 1.5mm diameter.
    • A 1mm deep notch in the bottom side of the weld.
  4. Critical Application: The weld’s application in aerospace demanded absolute accuracy and reliability.

Solution

Blue Star addressed the client’s challenges with a tailored solution combining advanced ultrasonic techniques:

  1. Time-of-Flight Diffraction (TOFD): This technique provided complete weld volume coverage, accurately detecting volumetric flaws such as side-drilled holes. The diffraction-based approach ensured precise results even with high attenuation.
  2. Phased Array Ultrasonics: This method focused on inspecting the root area of the weld. By steering ultrasonic beams at varying angles, it effectively detected critical defects like notches with high precision, especially in challenging geometries.

The integration of TOFD and Phased Array provided comprehensive coverage and accurate detection of flaws, overcoming the challenges posed by titanium’s grain structure and attenuation. This combination ensured compliance with stringent aerospace standards.

  • Advanced Technology: Blue Star leveraged cutting-edge ultrasonic methods to deliver reliable and accurate results.
  • Customized Solutions: The inspection approach was tailored to address the specific requirements of the client’s titanium welds.
  • Industry Expertise: Blue Star’s extensive experience in weld inspection ensured a seamless and efficient process.

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