NON DESTRUCTIVE

TESTING
OF AIRCRAFT PARTS
 Non Destructive Testing
• NDT is a method of inspection performed
on actual aircraft part and components,
either new or already in service without
causing any damage to the parts/component
• If the inspection does not reveal any flaw,
the aircraft parts and components are
certified and returned to service.
 Non Destructive Testing
• NDT is different from Destructive Tests.
• During destructive tests the part/component
get damaged or destroyed and hence cannot
be used.
• Destructive tests are carried out on
representative test specimens and not on
objects actually used in service.
 Non Destructive Testing
• Advantages of NDT :
• Does not damage the part while testing
• Tests are made directly upon the component
or part to be used in service
• Test can be made on every parts
• NDT permits repeated checks on parts/
components over a period of time.
 Non Destructive Testing
• Dis-advantages of NDT :
• Tests are mostly qualitative and not
quantitative.
• Skilled personnel are required to operate
complicated machines and to interpret the
test indications.
 Non Destructive Testing
• Airframe and Engine manufacturers/
Vendors have devised techniques for
particular NDT inspections, and these are
written into the appropriate Maintenance
Manuals, CMM, OHM or included in a
separate Non-destructive Testing (NDT)
manual.
 Types of NDT
• Visual Inspection
• Fluorescent Penetrant Inspection (FPI)
• Eddy Current
• Magnaflux
• Ultrasonic
• Radiographic
 Types of NDT
• Visual Inspection is one of the simplest
NDT technique for locating defects. Aids
such as magnifying glass, microscope,
intense light and boro-scope can enhance
visual tests.
• It is simple, inexpensive and fast.
• Detection of internal defects are not
possible for opaque objects.
 Types of NDT
• Coin Tap Test is very simple and quick.
• It uses a coin (approx. 25 mm dia. And 2.5
mm thick) to tap gently the surface of the
part under test.
• A clear sharp and ringing sound indicates a
well bonded solid structure
• A dull or thud sound indicates damaged or
relatively large void areas.
 Coin Tap Test
• Advantage of Coin Test is
• In-expensive and quick and can detect
internal defects.
• Disadvantage are that it is highly subjective
(depends on human ear which varies from
person to person) and cannot locate very
small defects.
• Not effective on parts having thick metal
skins.
 Fluorescent Penetrant Process
• FPI are used for detection of flaws of :
• Non ferrous and non-magnetic parts
• Ferrous parts
• Non metallic materials such as Plastics and
Ceramics
• Not suitable for use on absorbent materials
 FPI Principle
• FPI is based on the principle that when ultra
violet radiation falls on certain chemical
compounds (penetrant), it is absorbed and
its energy is re-emitted as visible light (that
is the wavelength of the light is changed)
 FPI Procedure
• A suitable chemical is allowed to penetrate
into surface cavities and flaws
• On application of developer, the penetrant is
drawn to the surface
• Cracks and flaws will be revealed by
brilliant greenish-yellow lines or patches
under the rays of an ultra-violet lamp.
 SURFACE PREPARATION
• The surface to be tested must be free from
oil, grease, paint, rust, scale, welding flux,
carbon deposits etc.
• If paint is present, remove paint from the
surface to be tested prior to cleaning.
Subsequent to the test, the surface may be
repainted.
 Application of Penetrant
• The penetrant can be applied to the surface
by dipping, spraying or brushing, depending
on the size, shape and quantity of parts to be
examined.
• Note : The parts must be completely dry
before the penetrant is applied.
 PENETRATION TIME
• The penetration time is the time which is to
be allowed for the penetrant to enter
effectively into the defects and flaws
• Usually ten minutes time is sufficient for
the larger type defects, but longer time may
be necessary where minute defects are
sought.
 Removal of Excess Penetrant
• Excess penetrant should be removed by
spraying with running water or by use of an
air/water gun.
 Application of Developer
• The developer usually consists of a very
fine white powder applied in the form of a
spray
• The developer should be applied evenly and
thinly, since a thick layer may completely
conceal a defect holding only a minute
quantity of dye.
 Defects
• After application of developer, allow the
parts to stand for at least 15 minutes
• Then examine the parts in a dark room,
using ultraviolet light.
• Where defects exist, they will be indicated
by brilliant greenish-yellow marks on the
surface of the part.
 Indication Interpretation
• The rate of staining is an indication of the
width and depth of the defect, whilst the
extent of staining is an indication of its
volume.
• A wide shallow defect is revealed almost
instantly, but narrow deep defects may take
some time to display the final pattern.
 Indication Interpretation
• Scattered dots indicate fine porosity or
pitting, whilst gross porosity may result in
an entire area becoming stained.
• Wide cracks, lack of fusion in welded parts
are indicated by continuous lines.
• All defects should be suitably marked prior
to removal of the developer
 Removal of Developer
• Developer should be removed by washing
with water spray or by dipping
• Apply the prescribed protective treatment
without delay.
 Removal of Developer
• Advantages are it is a simple method to
detect very small surface defects.
• Disadvantages are that only surface defects
can be detected. It is not a clean method.
Presence of penetrant in the material may
cause deterioration.
 Eddy Current Inspection
• Eddy current inspection detects :
• Surface cracks
• Corrosion
• Heat damaged skin
• Fastener holes for cracks
• Coating thickness measurement
• Sorting materials.
 Eddy Current Inspection
• Advantages of Eddy Current Inspection :
• Compact, portable battery powered sets can
be used in comparatively inaccessible
places in aircraft structure.
• They do not require extensive surface
preparation or removal of the part to be
tested, and give immediate test results.
• Improved sensitivity over other NDT
techniques.
 Eddy Current Inspection
• Dis-advantages of Eddy Current Inspection
is that it can detect only surface or near
surface defects. Eddy current inspection is
suitable for conductive materials only.
 Eddy Current Inspection
• Disadvantages of Eddy Current
• Depth of penetration
• Effects of surface coatings
• Unseen changes in geometry
• Test results relate only to the size of signal
received, and do not indicate size of defect.
• Only comparative type, a reference or
standard containing artificial defect required
 Principles of Eddy Current
• Eddy currents are induced in a electrically
conducting material when the material is
subjected to changing magnetic field, and
normally flow parallel to the surface of the
material.
 Principles of Eddy Current
• In Eddy Current testing a coil is supplied with
alternating current and held in contact with (or in
close proximity to) the test specimen. The
alternating magnetic field produced around the
coil induces an alternating eddy current in the
specimen, and the eddy current itself produces an
alternating magnetic field which opposes and
modifies the original coil field. The resultant
magnetic field is the source of information which
can be analysed to reveal the presence of flaws in
the test specimen.
 PENETRATION
• Eddy currents are strongest at the surface of
a material and weaken with depth.
• This effect becomes more pronounced with
increased frequency of the alternating
magnetic field and is known as ‘skin effect’
 Effects of Frequency
• When testing for surface cracks greater
sensitivity is obtained at higher frequency.
• For thin aluminum alloy sheet test
frequencies are between 5 kHz to 4 MHz,
depending on the defect sought.
• Frequencies as low as 50 Hz are used for
checking material properties (conductivity
to check hardness, heat treatment etc.)
 PROBES
• Probes used in Eddy Current do not require
a coupling fluid because they are connected
to the material by a magnetic field.
• To maintain the coils in close proximity to
the work, a probe is designed for one
particular use only.
 PROBES
• Probes used in aircraft work are designed
with a view to eliminate the need for
disassembly when carrying out routine
maintenance work. Probes commonly used
in aircraft work are :
• Surface Probes
• Hole Probes
• Special Probes
 PROBES
• Surface Probes used for detecting surface
cracks, coating thickness measurement or
conductivity tests
• Hole Probes used for detection of radial
cracks round fastener holes.
• Special Probes to suit different application
for detection of cracks in wheel bead seats,
turbine engine compressor, or turbine
blades.
 REFERENCE PIECES
• For calibration, standard reference pieces of
similar material containing defects of
known size and shape is used, so that the
change in coil impedance against a known
defect can be used as an acceptance limit.
• Reference pieces are usually small in size to
carry to test location.
 Ultrasonic Flaw detection
• Application and Scope :
• For detecting surface and internal flaws in
materials and parts
• For Thickness measurement
• De-lamination of bonded assemblies
• For detecting fatigue cracks and other
defects arising from operating conditions.
 Ultrasonic Flaw detection
• The sound waves used in Ultrasonic testing
are produced and detected by an Electo-
mechanical transducer, a device that
converts electrical energy into mechanical
energy and vice versa.
• Frequencies used in ultrasonic testing is at a
pitch too high to be detected by human ear,
within the range 500 kHz to 10 MHz
 Electro-mechanical transducer
• Piezo-electric effect :
• If a mechanical stress is applied to certain
natural crystals such as quartz, in a
specified direction, an electrical field is
produced in which the voltage is
proportional to the magnitude of the stress.
• Similarly if a voltage is applied between the
crystal faces a proportional mechanic stress
is produced in the crystal.
 Electro-mechanical transducer
• By applying an electrical potential to the
faces of an X-cut quartz crystal a vibration
is produced, the frequency of which depend
on the thickness of the crystal.
• Conversely, when such a crystal is caused to
vibrate under the influence of a sound beam
an alternating current is produced between
the crystal faces.
 ACOUSTIC COUPLING
• The coupling between metal and air is
extremely poor, and if any air is present
between a probe and the material being
tested very little energy will be transferred
across the interface.
• A liquid couplant such as water, oil or
grease is normally used in ultrasonic testing.
 PROBES
• A probe consists of a transducer mounted in
a damping material and connected
electrically to the test set.
• A probe is designed for a particular
application so that a sound beam is injected
into the material at an angle normal to the
expected defect.
 DISPLAY
• Information obtained in ultrasonic testing is
displayed by means of a cathode ray
oscilloscope.
 ULTRASONIC TESTING
• The importance of ultrasonic testing in situ,
is that defects and corrosion, can be found
in areas not accessible for visual
examination, provided that one smooth
surface is available to the probe.
• Ultrasonic gives quick results when the
defect is normal to the directed beam, which
even radiographic techniques find
unsuitable.
 ULTRASONIC TESTING
• The advantage of Ultrasonic inspection is
that it can indicate the depth of the defect.
• C-scan provides permanent record.
• Pulse echo method is very suitable for field
work.
 Magnetic Particle Inspection
• Magnetic Particle inspection is used to
detect surface and subsurface cracks in
ferro-magnetic materials, such as iron and
steel.
• It is not applicable to non-magnetic
materials.
 Magnetic Particle Inspection
• Magnetic Particle inspection detects the
location of the defect and outlines the
approximate size and shape.
• Defect is an interruption in the normal
physical structure or configuration of a part
such as a crack, forging lap, seam,
inclusion, porosity etc.
 Principle of Magnetic flaw
detection
• If a component is subjected to a magnetic
flux, any discontinuity in the material will
distort the magnetic field and cause local
leakage field at the surface.
• Particles of magnetic material applied to the
surface of the magnetized component will
be attracted to the flux leakage areas and
reveal the presence of discontinuity.
 Magnetic Particle Inspection
• This consist of magnetizing the part and
then applying ferromagnetic particles to the
surface area to be inspected.
• If defect is present, the magnetic lines of
force will be disturbed and opposite poles
will exist on either side of the discontinuity.
• The magnetic particles will form a pattern
(approx. shape of defect) in the magnetic
field between the opposite poles.
 MPI
• To detect a defect, the magnetic lines of
force must pass perpendicular to the defect.
• It is therefore, necessary to induce magnetic
flux in more than one direction. Two types
of magnetization are :
• Circular magnetization
• Longitudinal magnetization
 Circular Magnetization
• Circular magnetization is induced by
passing electric current through the part.
This will induce magnetic field, consisting
of concentric circles of force about and
within the part.
• This will detect defects that run approx.
parallel to the axis of the part.
 Longitudinal Magnetization
• Longitudinal magnetization is accomplished
by placing the part in a solenoid excited by
electric current.The part becomes the core
of an electromagnet and is magnetized by
induction from the magnetic field created in
the solenoid.
• This will detect defects that exist perpendi-
cular to the axis of the part.
 Magnetic Particles
• The magnetic particles used to reveal
defects are either in the form of a dry
powder or suspended in a suitable liquid.
• They may be applied by spray, pouring or
immersion
• Fluorescent inks and black light are often
specified where high sensitivity is required.
 DEMAGNETIZATION
• After inspection demagnetize the part, and
subsequently do not bring the part at the
vicinity of the demagnetizing coil, the
testing machine, or any other magnetized
material.
• Test for the demagnetization of parts. The
standard test is the deflection of a magnetic
compass needle under controlled conditions.
 DEMAGNETIZATION
• The advantage of Magnflux is that it is
sensitive to small defects.
• The disadvantages are that it can be used for
ferro-magnetic materials only.
• It can only detect surface or near surface
defects.
 RADIOGRAPHY
• Radiography inspection techniques are used
to locate defects in airframe structures or
engine with little or no disassembly or
stripping of paint.
• Compact unit, fast and reliable results
• Radiography is of value in providing second
opinion where inconclusive results have
been obtained by other methods of NDT.
 RADIOGRAPHY
• Two forms of electro-magnetic radiations
are used in radiography
• X-ray
• Gamma rays
 RADIOGRAPHY
• The radiations are of very short wave length
• They are capable of penetrating solids and
disclose defects and discontinuities.
• The penetrating radiation when projected
through a test piece, produces a latent image
in the film, which when processed becomes
a radiograph or shadow picture of the
object.
 X-RAYS
• X-rays are produced when electrons,
travelling at high speed collide with matter
in any form.
• The portable sets used in aircraft work
typically cover ranges of 10kV to 100kV
and 100kV to 250kV
 GAMMA RAYS
• Gamma rays result from the disintegration
of radioactive materials
• The isotopes used are artificially produced
and emit rays of similar wavelength to those
produced in X-ray tubes.
• Commonly used isotopes are Cobalt 60,
Iridium 192, Caesium 137 and Thulium 170
 GAMMA RAYS
• Gamma ray sources consist of a circular
disc or cylinder of radioactive material
encased in a sealed aluminum or stainless
steel capsule.
• The capsule is kept in a lead container
• Since gamma rays cannot be turned off,
strict regulations exist during transportion
and used of radioactive sources.
 GAMMA RAYS
• Unsharpness and lack of contrast are
normally obtained with Gamma ray sources
and therefore majority of radiographs of
aircraft structures are taken with an X-ray
set
• However, there are occasions when a
gamma source is used, mainly due to lack of
space or access for X-ray equipment.
 RADIOGRAPHY
• The film used in radiography are very
similar to those used in photography except
that the emulsion covers both sides of the
flexible transparent base.
• The emulsion is sensitive to X-rays, gamma
rays and light, and when exposed a change
takes place in its physical structure.
 RADIOGRAPHY
• After exposure when the film is treated with
a developer, a chemical reaction results in
the formation of black metallic silver which
comprises the image.
• All processing is done in a ‘dark room’
illuminated by subdued yellow light to
which the film is not readily sensitive.
 Radiographic Interpretations
• Radiographic interpretation is the most
important phase of radiography.
• Radiographic interpretation should be done
close to the radiographic operation to
compare directly with the material tested
and indications due to such things as surface
condition or thickness variations.
 Radiation Hazards
• Radiation from X-ray and gamma sources is
destructive to living tissues, and excess dose
may cause irreparable harm, even death
• The skin absorbs most of the radiation and
reacts earliest. Blood and intestinal
disorders result in short period of time.
• Delayed effects are leukemia and cancer
• Other effects are skin damage and loss of
hair
 Radiation Hazards
• The following precautions are essential :
• Radiographers should be fully qualified and
adequately trained.
• Only qualified radiographers must be
allowed to operate radiographic units.
• Do not misuse radiographic equipment
which could release dangerous radiation.
 Radiation Hazards
• Advantages
• Ability to inspect part covered or hidden by
other parts, and provides permanent records
• Disadvantages are it is expensive and
requires considerable safety protection.
• Defects oriented normal to the radiation are
often difficult to detect.
 ENDOSCOPE INSPECTIONS
• Condition monitored gas turbine engines are
allowed to remain in service until defects
are revealed via performance monitoring
analysis, oil analysis, endoscope inspection
or by repetitive monitoring of allowable
damage.
• Use of Endoscope is to avoid high cost of
engine change due to suspected internal
damage.