5.1 PCRT Applications and Capabilites—PCRT has been applied successfully to a wide range of outlier screening applications in the manufacture and maintenance of metallic and non-metallic parts. Examples of anomalies detected are discussed in 1.1. PCRT has been shown to provide cost effective and accurate outlier screening solutions in many industries including automotive, aerospace, and power generation. Examples of successful applications currently employed in commercial use include, but are not limited to:

(1) Silicon nitride bearing elements,

(2) Steel, iron, and aluminum rocker and control arms,

(3) Gas turbine engine components (blades, vanes, disks),

(4) Cast cylinder heads and cylinder blocks,

(5) Sintered powder metal gears and clutch plates,

(6) Machined forged steel steering and transmission components (gears, shafts, racks),

(7) Ceramic oxygen sensors,

(8) Silicon wafers,

(9) Gears with induction hardened teeth,

(10) Ceramic matrix composite (CMC) material samples and components,

(11) Components with shot peened surfaces,

(12) Machined and/or rolled-formed steel fasteners, and

(13) Additive manufactured components.

5.2 General Approach and Equipment Requirements for PCRT via Swept Sine Input: 

5.2.1 PCRT systems are comprised of hardware and software capable of inducing vibrations, recording the component response to the induced vibrations, and executing analysis of the data collected. Inputting a swept sine wave into the part has proven to be an effective means of introducing mechanical vibration, and can be achieved with a high quality signal generator coupled with an appropriate active transducer in physical contact with the part. Collection of the part’s frequency response can be achieved by recording the signal generated by an appropriate passive vibration transducer. The software required to analyze the available data may include a variety of suitable statistical analysis and pattern recognition tools. Measurement accuracy and repeatability are extremely important to the application of PCRT.

5.2.2 Hardware Requirements—A swept sine wave signal generator and response measurement system operating over the desired frequency range of the test part are required with accuracy better than 0.002 %. The signal generator should be calibrated to applicable industry standards. Transducers must be operable over same frequency range. Three transducers are typically used; one “drive” transducer and two “receive” transducers. Transducers typically operate in a dry environment, providing direct contact coupling to the part under examination. However, noncontacting response methods can operate suitably when parts are wet or oil-coated. Other than fixturing and transducer contact, no other contact with the part is allowed as these mechanical forces dampen certain vibrations. For optimal examination, parts should be placed precisely on the transducers (generally, ±0.062 in. (1.6 mm) in each axis provides acceptable results). The examination nest and cabling shall isolate the drive from receive signals and ground returns, so as to not produce (mechanical or electrical) cross talk between channels. Excessive external vibration or audible noise, or both, will compromise the measurements.

5.3 Constraints and Limitations: 

5.3.1 PCRT cannot separate parts based on visually detectable anomalies that do not affect the structural integrity of the part. It may be necessary to provide additional visual inspection of parts to identify these indications.

5.3.2 Excessive process variation of parts may limit the sensitivity of PCRT outlier screening.

5.3.3 Specific anomaly identification is highly unlikely. PCRT is a whole body measurement, and differentiating between a crack and a void in the same location is generally not possible. It may be possible to differentiate some anomalies by using multiple patterns and teaching sets.

5.3.4 PCRT will only work with stiff objects that provide resonances whose peak quality factor (Q) values are greater than 500. Non-rigid materials or very thin-walled parts may not yield satisfactory Q values.

5.3.5 While PCRT can be applied to painted and coated parts in many cases, the presence of some surface coatings such as vibration absorbing materials and heavy oil layers may limit or preclude the application of PCRT.

5.3.6 While PCRT can be applied to parts over a wide range of temperatures, it cannot be applied to parts that are rapidly changing temperature. The part temperature should be stabilized before collecting resonance data.

5.3.7 Misclassified parts in the teaching set, along with the presence of unknown anomalies in the teaching set, can significantly reduce the accuracy and sensitivity of PCRT.

1.1 This practice describes a general procedure for using the process compensated resonance testing (PCRT) via swept sine input method to perform outlier screening on populations of newly manufactured and in-service parts. PCRT excites the resonance frequencies of metallic and non-metallic test components using a swept sine wave input over a set frequency range. PCRT detects and analyzes component resonance frequency patterns, and uses the differences in resonance patterns between acceptable and unacceptable components to perform non-destructive testing. PCRT frequency analysis compares the resonance pattern of a component to the patterns of known acceptable and unacceptable populations of the same component, and renders a pass or fail result based on the similarity of the tested component to those populations. For non-destructive testing applications with known defects or material states of interest, or both, Practice E2534 covers the development and application of PCRT sorting modules that compare test components to known acceptable and unacceptable component populations. However, some applications do not have physical examples of components with known defects or material states. Other applications experience isolated component failures with unknown causes or causes that propagate from defects that are beyond the sensitivity of the current required inspections, or both. In these cases, PCRT is applied in an outlier screening mode that develops a sorting module using only a population of presumed acceptable production components, and then compares test components for similarity to that presumed acceptable population. The resonance differences can be used to distinguish acceptable components with normal process variation from outlier components that may have material states or defects, or both, that will cause performance deficiencies. These material states and defects include, but are not limited to, cracks, voids, porosity, shrink, inclusions, discontinuities, grain and crystalline structure differences, density-related anomalies, heat treatment variations, material elastic property differences, residual stress, and dimensional variations. This practice is intended for use with instruments capable of exciting, measuring, recording, and analyzing multiple, whole body, mechanical vibration resonance frequencies in acoustic or ultrasonic frequency ranges, or both.

1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.

1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. Some specific hazards statements are given in Section 7 on Hazards.