The preceding information in this chapter provided general details regarding aircraft inspection. The remainder of this chapter deals with several methods often used on specific components or areas on an aircraft when carrying out the more specific inspections. They are referred to as nondestructive inspection (NDI) or nondestructive testing (NDT). The objective of NDI and NDT is to determine the airworthiness of a component, without damaging it, that would render it unairworthy. Some of these methods are simple, requiring little additional expertise, while others are highly sophisticated and require that the technician be highly trained and specially certified.
Training, Qualification, and Certification
The product manufacturer or the FAA generally specifies the particular NDI method and procedure to be used in inspection. These NDI requirements are specified in the manufacturer’s inspection, maintenance, or overhaul manual, FAA ADs, supplemental structural inspection documents (SSID), or SBs.
The success of any NDI method and procedure depends upon the knowledge, skill, and experience of the NDI personnel involved. The person(s) responsible for detecting and interpreting indications, such as eddy current, x-ray, or ultrasonic NDI, must be qualified and certified to specific FAA or other acceptable government or industry standards, such as MIL-STD-410, Nondestructive Testing Personnel Qualification and Certification or A4A iSPec 2200, Guidelines for Training and Qualifying Personnel in Nondestructive Testing Methods. The person must be familiar with the test method, know the potential types of discontinuities peculiar to the material, and be familiar with their effect on the structural integrity of the part. Additional information on NDI may be found by referring to Chapter 5 of FAA AC 43.13-1, Acceptable Methods, Techniques, and Practices—Aircraft Inspection and Repair.
Advantages and Disadvantages of NDI Methods
Figure 10-6 provides a table of the advantages and disadvantages of common NDI methods. This table could be used as a guide for evaluating the most appropriate NDI method when the manufacturer or the FAA has not specified a particular NDI method to be used.
General Techniques
Before conducting NDI, it is necessary to follow preparatory steps in accordance with procedures specific to that type of inspection. Generally, the parts or areas must be thoroughly cleaned. Some parts must be removed from the aircraft or engine. Others might need to have any paint or protective coating stripped. A complete knowledge of the equipment and procedures is essential and, if required, calibration and inspection of the equipment must be current.
Visual Inspection
Visual inspection can be enhanced by looking at the suspect area with a bright light, a magnifying glass, and a mirror. Some defects might be so obvious that further inspection methods are not required. The lack of visible defects does not necessarily mean further inspection is unnecessary. Some defects may lie beneath the surface or may be so small that the human eye, even with the assistance of a magnifying glass, cannot detect them.
Surface Cracks
When searching for surface cracks with a flashlight, direct the light beam at a 5 to 45 degree angle to the inspection surface towards the face. [Figure 10-7] Do not direct the light beam at such an angle that the reflected light beam shines directly into the eyes. Keep the eyes above the reflected light beam during the inspection. Determine the extent of any cracks found by directing the light beam at right angles to the crack and tracing its length. Use a 10-power magnifying glass to confirm the existence of a suspected crack. If this is not adequate, use other NDI techniques, such as penetrant, magnetic particle, or eddy current to verify cracks.
Borescope
Inspection by use of a borescope is essentially a visual inspection. A borescope is a device that enables the inspector to see inside areas that could not otherwise be inspected without disassembly. Borescopes are used in aircraft and engine maintenance programs to reduce or eliminate the need for costly teardowns. Aircraft turbine engines have access ports that are specifically designed for borescopes. Borescopes are also used extensively in a variety of aviation maintenance programs to determine the airworthiness of difficult to reach components. Borescopes typically are used to inspect interiors of hydraulic cylinders and valves for pitting, scoring, porosity, and tool marks; search for cracked cylinders in aircraft reciprocating engines; inspect turbojet engine turbine blades and combustion cans; verify the proper placement and fit of seals, bonds, gaskets, and subassemblies in difficult to reach areas; and assess foreign object damage (FOD) in aircraft, airframe, and powerplants. Borescopes may also be used to locate and retrieve foreign objects in engines and airframes.
Borescopes are available in two basic configurations. The simpler of the two is a rigid type, small diameter telescope with a tiny mirror at the end that enables the user to see around corners. The other type uses fiber optics that enable greater flexibility. [Figure 10-8] Many borescopes provide images that can be displayed on a computer or video monitor for better interpretation of what is being viewed and to record images for future reference. Most borescopes also include a light to illuminate the area being viewed.
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