Acoustic Emission Methods for the Health Evaluation of Integrated Pressure Components
At the request of the Pressure Systems Senior Discipline Expert, to overcome the access and detectable flaw size limitations of other nondestructive evaluation (NDE) methods for integrated components, a technique akin to seismology was advanced to perceive the earliest signs of cracking in titanium components before they escalate into serious issues. In this project we achieved a landmark in Acoustic Emission (AE) testing with the first NASA Probability of Detection (POD) study. This is an important first step to the certification of the AE method for flight components and was based on the testing of notched panels. By working closely with industry allies and employing approved methods from the boiler and pressure vessel sector, we not only met but surpassed all POD benchmarks with our test and acceptance criteria. In experiments involving solution heat-treated and aged 6Al-4V-Ti alloy tested with broadband sensors, we recorded a 96% success rate, with zero false positives reported. Our research shows that in some cases, AE testing can locate smaller cracks than other NDE methods. An industry tool for scaling results to full pressure vessels is highlighted. However, before applying our findings to NASA components, tests to validate the transfer functions are advised.