Development of in-process NDE machining force feedback analysis for titanium alloy component texture analysis

Titanium aerospace alloys are machined using a turning operation, in which the force data from the operation is used to produce images of what the surface looks like. It is a non-destructive technique that performs similarly to ultrasonic testing and EBSD in that it can identify defects and macrozones in the material.

One of the current issues in the production of titanium aerospace alloys is its extremely high costs due to the importance of safety. Every component undergoes a series of tests to guarantee issues are found before the material takes to the air.

By producing a technique that works during the machining process, an additional and potentially alternative non-destructive testing (NDT) can be used. By including it in the manufacturing process no additional cost (other than the relatively simple and cheap equipment) is incurred in comparison to all other techniques. Additionally, it doesn't require extreme expertise to capture and analyse the data, meaning there are also time and money savings all round with this method.

The method of force response mapping (FRM) captures force data that is normally ignored, and is manipulated in a way that it relates details on the surface and sub-surface of material. This means defects can be found, and the material analysed further. The small kit involved in FRM solves the issues of cost and time for the aerospace industry, whilst maintaining the safety of the materials manufactured.

Developing FRM has been an extremely rewarding experience due to the collaboration with Rolls-Royce. It enables me to see the importance of improving this novel technique and to know that it will help ensure the safety of aerospace components provides me with a great sense of pride.

Dillon Frith

FRM is a strong alternative to other NDT methods and only offers an improvement of safety in the manufacturing of materials. By providing an additional test of aerospace components, there is another layer of safety added to the materials. Primarily, the technique can be applied to the aerospace industry; however, FRM can be used in all areas in which material testing is necessary, e.g. automotive, mechanical etc. On an individual user level, this improves safety assessments for everyday travel such as cars and aircrafts. Finding issues in materials can be difficult, so having a technique that has the capability to identify defects is crucial and leads to improvements all round.

Equipment Used

• DMG MORI NLX 2500 - AMRC Catcliffe
• FCT H-HP D25 - RDC Sheffield
• Open-die Forging Press - AFRC Glasgow

Biography

Dillon Frith holds a BSc in Physics and an MSc in Nanomaterials and Materials Science from the University of Sheffield, where his thesis focused on developing advanced titanium alloys using Field-Assisted Sintering Technology. He is currently pursuing an EngD in partnership with Rolls-Royce at the University of Sheffield, with research centred on the development of Force Response Mapping, a novel non-destructive testing technique for assessing titanium aerospace components.