The Boeing Company

Joseph A Pecina

Gary Backhaus

Ryan J Glamm

Michael S Carr

Robert Burkett

Gary M Backhaus

Standards for non-destructive testing methodologies and methods of fabricating the standards are disclosed herein. The standards include a void-defect coupon that includes a spheroidal void and an elongated void. The spheroidal void has a maximum dimension and a spheroidal void volume. The elongated void had a longitudinal dimension, a maximum transverse dimension, and an elongated void volume. The longitudinal dimension of the elongated void is greater than the maximum dimension of the spheroidal void. The maximum transverse dimension of the elongated void is less than the maximum dimension of the spheroidal void. The methods include forming a first void-defect coupon and forming a second void-defect coupon.

Standards for non-destructive testing methodologies and methods of fabricating the standards

A method for nondestructive testing includes steps of: (1) forming a first inspection standard using a metal injection molding process; (2) forming a second inspection standard using the metal injection molding process; and (3) creating a reference library that includes the first inspection standard and the second inspection standard. The first inspection standard includes first voids that are induced by a first set of conditions of a sintering operation and a hot isostatic pressing operation of the metal injection molding process. The second inspection standard includes second voids that are induced by a second set of the conditions of the sintering operation and the hot isostatic pressing operation. At least one of the conditions in the second set of the conditions is different than at least one of the conditions of the first set of the conditions. The first voids and the second voids are different.

System and method for inspecting components fabricated using a powder metallurgy process

A method of removing flash from a gauge portion of a monolithic precursor test coupon using a flash-removal tool is provided. The flash-removal tool comprises a tool body, extending along a longitudinal tool axis, a tooth, and an engagement surface, spaced apart from the tooth along the longitudinal tool axis. The tooth projects from the tool body in a first direction and comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The method comprises steps of coupling the engagement surface of the flash-removal tool against a first precursor-coupon end of the monolithic precursor test coupon, orienting the longitudinal tool axis parallel to a longitudinal symmetry axis of the monolithic precursor test coupon, wherein the shearing surface registers longitudinally with the flash, and shearing, using the shearing surface, the flash from the gauge portion.

Monolithic precursor test coupons for testing material properties of metal-injection-molded components and methods and apparatuses for making such coupons

A method of making a test coupon using a mold is provided. The mold defines a mold cavity that comprises a first-grip-portion cavity, a second-grip-portion cavity, an intermediate-portion cavity, interconnecting the first-grip-portion cavity and the second-grip-portion cavity, and runner cavities, directly interconnecting the first-grip-portion cavity and the second-grip-portion cavity and not directly connected to the intermediate-portion cavity. The method comprises injecting feedstock material, comprising a metal powder, into the mold cavity to form a monolithic precursor test coupon in the mold cavity, wherein the monolithic precursor test coupon comprises a first grip portion, a second grip portion, an intermediate portion, and runners. The method also comprises removing the runners from the monolithic precursor test coupon.

A flash-removal tool comprises a tool body, extending along a longitudinal tool axis, and a tooth, projecting from the tool body in a first direction. The flash-removal tool further comprises an engagement surface, perpendicular to the longitudinal tool axis and located a preselected distance away from the tooth along the longitudinal tool axis. The tooth comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis.

Flash-removal tool

A monolithic precursor test coupon includes a first grip portion, a second grip portion, and an intermediate portion, interconnecting the first grip portion and the second grip portion. The monolithic precursor test coupon also includes runners, directly interconnecting the first grip portion and the second grip portion and not directly connected to the intermediate portion. The first grip portion, the second grip portion, the intermediate portion, and the runners are composed of a substance that comprises metal powder and that is in a green state.

Growing community of inventors

Lynnwood, WA, United States of America

Joseph A Pecina