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Building a Cad-Native Digital Twin for Ndt and Plm: Workflow, Tools, and Case Study

Sobociński Miłosz, Synaszko Piotr, Dragan Krzysztof, Kotowski Jakub

Fatigue of Aircraft Structures

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2024

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Iss.16

161--187

EN

Digital twins (DTs) can connect inspection data with product models to support safer, more efficient lifecycle decisions. This paper proposes a CAD-native workflow for implementing a digital twin that visualizes and manages non-destructive testing (NDT) results directly on a 3D model. The method supports over-the-surface data (ultrasonic C-scans, UT) via UV mapping and projected images (thermography, TT) via planar projection, both executed in Siemens NX with custom macros for point localization and on-surface measurement. We validate the approach on a bottom nacelle panel from a Honeywell HTF7000 turbofan engine, acquired via 3D scanning and reverse engineering. The resulting digital twin preserves a persistent spatial link between inspection images and geometry, enables remote sizing and review, and centralizes result management in the CAD environment for PLM use cases (e.g., defect history, trend analysis). Timelines indicate higher initial effort but reduced on-site workload and travel for qualified inspectors thereafter. Limitations include large file sizes when storing geometry and multiple images in a single model; we outline a lightweight distribution strategy and future automation/VR enhancements. The findings demonstrate the feasibility and practical value of CAD-resident digital twins for NDT visualization, remote evaluation, and product lifecycle management.

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Sorption in an ammonioalunite-ammoniojarosite solid solution: results for the 1, 2, 4, 7, 11, 12 and 13 group elements and LREEs

Kruszewski Łukasz, Marciniak-Maliszewska Beata, Kotowski Jakub

Geological Quarterly

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2023

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Vol. 67, No. 4

art. no. 46

EN

This paper collates selected analytical results from a 1-year sorption experiments conducted on natural samples of an ammonioalunite-ammoniojarosite solid solution (AAJ) of known initial composition. These include Electron Microprobe (EPMA) and Powder X-Ray Diffraction (PXRD) results for baths subjected to Li2SO4·H2O, KI, Rb2CO3 (0.33-0.62 wt.% Rb2O in the AAJ, CsCl (0.24-1.07 wt.% Cs2O), Ca(OH)2 (ettringite formation), Sr(NO3)2 (0.31–10.25 wt.% SrO), ZrO(NO3)2·2H2O, MnSO42O, CuSO4·5H2O (up to 1.05 wt.% CuO), ZnCl2, Ga(NO3)3·9H2O (5.86-21.44 wt.% Ga2O3), ZrCl4 (up to 17.56 wt.% ZrO2 in AAJ, i.e., up to 0.27 apfu Zr, InCl3 (0.85–17.04 wt.% In2O3, i.e., possibly up to 0.42 apfu), KH2AsO4 (up to 45.93 wt.% As2O5, recast to 1.64 apfu As), K2SeO3 (up to 44.86 wt.% SeO2, recast to 1.55 apfu Se), LaCl3·7H2O (0.17–0.22 wt.% La2O3), CeCl3·7H2O (0.38–1.74 wt.% Ce2O3), and PrCl3·6H-2O (1.66–4.10 wt.% Pr2O3). Zn, Mn, and I only rarely show accumulation. (NH4)Fe3(AsO4)2[(OH)4(H2O)2] and (NH4)Fe3[(AsO4)(SO4)][(OH)5(H2O)] are occasionally the dominant hypothetical end-members in the As experiment. In the KI case the resulting material is 1.6 times more enriched in K than the base used. Special attention is paid to Zr, with PXRD and EPMA results not ideally coincident with a trial Scanning Electron Microscopy-Electron Backscatter Diffraction study suggesting deposition of tetragonal ZrSiO4 (synthetic zircon).

3

Using Corrosion Health Monitoring Systems to Detect Corrosion: Real-Time Monitoring to Maintain the Integrity of the Structure

Ciężak Patryk, Vazquez-Gomez Loudres, Mattarozzi Luca, Benedetti Alessandro, Kotowski Jakub, Synaszko Piotr, Dragan Krzysztof, Głowacki Dominik, Wawryn Konrad

Fatigue of Aircraft Structures

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2023

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Iss.15

166--182

EN

This study investigates the use of Corrosion Health Monitoring (CHM) systems to detect and manage corrosion in aviation environments, with a specific focus on enclosed areas within aircraft structures. Corrosion poses significant risks to airport facilities and aircraft, and CHM systems offer real-time monitoring and data-driven approaches for proactive corrosion management. Through case studies conducted at two different test sites, the effectiveness of deploying advanced sensors was demonstrated in identifying corrosion-prone areas, optimizing maintenance schedules, and enhancing safety and structural integrity. The study highlights the variability in corrosion rates between open-air and enclosed conditions, emphasizing the need for tailored prevention strategies. It also discusses the challenges of integrating CHM systems into existing maintenance practices and airport infrastructure, addressing issues such as sensor placement, data management, and regulatory compliance, and outlines future directions for R&D in this critical area. By incorporating CHM systems, the aviation industry can transition from reactive to predictive maintenance, improving the reliability and lifespan of assets while reducing costs.

4

Detrital heavy minerals as guides to provenance of Albian arenites of southern extra-Carpathian Poland

Kotowski Jakub, Olszewska-Nejbert Danuta, Nejbert Krzysztof

Acta Geologica Polonica

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2023

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Vol. 73, no. 4

801--832

EN

The potential of heavy minerals as a provenance tracer in Albian arenites of extra-Carpathian Poland was assessed. Studies in this area have focused on various methods based on heavy mineral chemistry that provide an effective tool for reconstructing the provenance of quartz-rich sediments. The previously suggested division of the study area into two domains with different source areas: the western domain – the Miechów area, and the eastern domain – the Lublin area, was based on geochronological (monazite and muscovite dating) and rutile mineral chemical studies. The mineral chemistry of newly examined heavy minerals supports the previously suggested division. The mineral chemistry of detrital tourmaline suggests medium-grade metamorphic rocks as the main source in both domains. Detrital garnet in the western domain shows affiliation to the Góry Sowie Massif, while garnet in the eastern domain was most probably sourced from southern/central Norway. The western domain was most probably fed from rocks of the Bohemian Massif. The main source area for the eastern domain was most probably located in the Baltic Shield. The distinct division of the study area into two domains was caused by the palaeogeography of the region in the Albian and the action of longshore currents in south-eastward and eastward directions.

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Zirconium silicates in a peralkaline granite: a record of the interplay of magmatic and hydrothermal processes (Ilímaussaq complex, Greenland)

Cegiełka Małgorzata, Bagiński Bogusław, Macdonald Ray, Belkin Harvey E., Kotowski Jakub, Upton Brian G. J.

Acta Geologica Polonica

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2022

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Vol. 72, no. 2

235--245

EN

Compositional and textural data are presented for zircon, secondary Zr-silicates, catapleiite and elpidite in a peralkaline granite from the Ilímaussaq complex, south Greenland. The zircon is essentially stoichiometric, with (Zr + Hf + Si) = 1.96–1.98 a.p.f.u. The secondary Zr-silicates show a wide range of Zr/Si atomic ratios (0.13–0.79). The catapleiite varies from close to stoichiometric to a Na-depleted type showing cation deficiency (5.2–5.8 a.p.f.u.). Elpidite shows similar variations (7.2–9.0 a.p.f.u.). Textural relationships between the Zr phases are interpreted to show that magmatic zircon interacted with hydrous fluids exsolved from the magma to form the secondary Zr-silicates. Formation of catapleiite was late-magmatic, in equilibrium with a Na-Si-bearing fluid. This was followed by the crystallization of elpidite, the fluid having a different Na/Si ratio. Both catapleiite and elpidite experienced Na-loss during late-stage hydrothermal alteration.

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Chevkinite-group minerals in Poland

Nejbert Krzysztof, Bagiński Bogusław, Kotowski Jakub, Jokubauskas Petras, Jurewicz Edyta, Macdonald Ray

Acta Geologica Polonica

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2020

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Vol. 70, no. 1

97--106

EN

The chevkinite group of minerals are REE,Ti-silicates increasingly recognized as widespread accessory phases in a wide range of igneous and metamorphic parageneses. Members of the group are here recorded from five localities in Poland: a two-pyroxene andesite from the Kłodzko-Złoty Stok intrusion, a trachyandesite intrusion north of the Pieniny Mountains, a rapakivi-type granite from the Krasnopol intrusion, an anorthosite from the Suwałki Anorthosite Massif, and nepheline syenite from the Ełk syenite massif. Specific members found are chevkinite-(Ce), perrierite-(Ce) and, potentially, the Al-dominant analogue of perrierite-(Ce). The case is made that chevkinite-group minerals will, through systematic investigation, be found in a wide range of Polish igneous and metamorphic rocks.