The application of generic flaw sizing techniques to specific components generally involves difficulties associated with geometrical complexity and simplifications arising from a knowledge of the expected flaw distribution. This paper is concerned with the case of ultrasonic flaw sizing in turbine engine rotor components. The sizing of flat penny shaped cracks in the web geometry will be discussed and new crack sizing algorithms based on the Born and Kirchhoff approximations will be introduced. Additionally we propose a simple method for finding the size of a flat, penny shaped crack given only the magnitude of the scattering amplitude. The bore geometry is discussed with primary emphasis on the cylindrical focussing of the incident beam. Important questions which are addressed include the effects of diffraction and the position of the flaw with respect to the focal line. The appropriate deconvolution procedures to account for these effects will be introduced. Generic features of the theory will be compared with experiment. Finally, the effects of focused transducers on the Born inversion algorithm are discussed.
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