INSPECTION

FUNDAMENTALS
 DEFINITION

Inspection means “….An examination

of an item and comparison against
a specific standard”.
Inspection system consists :

1. Regularly scheduled
inspections of an
aircraft.
2. Reports made by
mechanics or by the
pilot or crew flying an
aircraft and
 INSPECTION METHODS

• Numerous inspection methods

may be used, and would not
restrict the use of higher level
or more intense methods to
satisfy the technician/inspector.
• When unsatisfactory condition
encountered, additional
methods may be employed
such as : the use of inspection
aids; removal of access panel
or component.
 BASIC INSPETION TASKS

1. Inspection; Examination against specific

standard.
2. Non-Destructive Inspection; To
supplement visual inspection and/or
detect hidden defects
3. Age Exploration
• Analysis of collected information from in-
service experience.
• Access resistance to deterioration
process with respect to increasing age.
 STRUCTURAL INSPECTIONS

1. General Visual,
– Exposed areas of wings, fuselage, doors, doors cut out and wheel wells.

2. External Surveillance,
– From a distance considered necessary to carry out adequate check,
3. Internal Surveillance
– From a distance considered necessary to carry out adequate check,

4. Detailed External or Internal,

– Close intensive visual of highly defined structural details or locations.

5. Special Detailed.
– Specific locations or hidden details using specified NDI procedures.
Inspection Techniques

• Before starting an inspection, be

certain all plates, access doors,
fairings, and cowling have been
opened or removed and the structure
cleaned.
• When opening inspection plates and
cowling, and before cleaning the area
take note of any oil or other evidence
of fluid leakage.
 REQUIRED INSPECTION ITEMS (RII)

 Defined as those maintenance and alteration which if not performed

properly, or if improper parts or material are used, could result in
endangering the aircraft operation safety;

 Persons performing RII are considered to be under the supervision and

control of quality assurance;

 Decision of authorized RII inspector shall not be countermanded without

approval of Director/Manager Quality Assurance or his designee;

 The person who perform can not inspect, the person who inspect can not
perform;

 The person shall be appropriately certified, properly trained, qualified and

authorized by Quality Assurance.
Checklist

• Always use a checklist when performing the

inspection.
• The checklist may be of your own design, one
provided by the manufacturer of the
equipment/ aircraft/ engine ect being
inspected, or one obtained from some other
source.
The checklist should include the following:
1. Fuselage and hull
group.
2. Cabin and cockpit
group.
3. Engine and nacelle
group.
4. Landing gear group.
5. Wing and center
section.
6. Empennage group.
7. Propeller group.
8. Communication and
navigation group.
9. Miscellaneous.
Aircraft Logs
• "Aircraft logs" as used in this handbook is an inclusive
term which applies to the aircraft logbook and all
supplemental records concerned with the aircraft.
• The logs and records provide a history of maintenance
and operation, control of maintenance schedules, and
data for time replacements of components or
accessories.
• The aircraft logbook is the record in which all data
concerning the aircraft is recorded.
• Information gathered in this log is used to determine the
aircraft condition, date of inspections, time on airframe
and engines.
• It reflects a history of all significant events occurring to
the aircraft, its components, and accessories, and
provides a place for indicating compliance with FAA
Airworthiness Directives or manufacturers' service
bulletins.
Special Inspections

1. Hard or Overweight
Landing Inspection

2. Severe Turbulence
Inspection
Publications

• Bulletins
• Maintenance manual
• Overhaul Manual
• Structural Repair Manual
• Federal Aviation
Regulations (FAR)
• Airworthiness Directives
• Type Certificate Data
Sheets
A.T.A. Specification No. 100

• The Air Transport Association of America (A.T.A.) issued the specifications

for Manufacturers Technical Data June 1, 1956.
Quote: "This specification establishes a standard for the presentation of technical
data, by an aircraft, aircraft accessory, or component manufacturer required for
their respective products."
Quote: "In order to standardize the treatment of subject matter and to simplify the
user's problem in locating instructions, a uniform method of arranging material in
all publications has been developed."
• The A.T.A. Specification 100 has the aircraft divided into systems such as
electrical which covers the basic electrical system (ATA 2400).
• Numbering in each major system provides an arrangement for breaking the
system down into several subsystems. Late model aircraft, both over and
under the 12,500 dividing line, have their parts manuals and maintenance
manuals arranged according to the A.T.A. coded system.
Non-destructive Inspection
(NDT)
Preview
DEFINITION

The use of noninvasive

techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.

i.e. Inspect or measure without doing harm.

Most Common NDT Methods
• Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• Eddy Current
• X-ray
VISUAL INSPECTION

• Visual inspection is defined as the process

of using the eye, alone or in conjunction
with various aids, as the sensing
mechanism from which judgments may be
made about the condition of a unit to be
inspected.
VISUAL INSPECTION
Most basic and common
inspection method.

Tools include
fiberscopes,
borescopes, magnifying
glasses and mirrors.

Portable video inspection

unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous
or tight areas, such as air
ducts, reactors, pipelines.
VISUAL INSPECTION

• Over 80% of the inspections on large transport

category aircraft are visual inspection.
• Visual inspection is usually the most economical
and fastest way to obtain an early assessment
of the condition of aircraft and its components.
• Most of the defect found on aircraft are found by
visual inspections, and the airframe
manufacturers and users depend on regular
visual inspection to ensure the continued
airworthiness of their aircraft
VISUAL INSPECTION

• Proficiency in visual inspection is crucial to the safe

operation of aircraft.
• Such proficiency is gotten from the experience, but also
by learning the methods developed by others.
• Visual inspection is an essential part of airplane
maintenance.
• The visual inspection component of NDI required trained
and experience personnel, using validated procedures,
and appropriate calibration standard with effective, well
maintained equipment in a well-managed maintenance
environment
Visual Inspection
• Nondestructive testing by visual
means is the oldest method of
inspection.
• Defects which would escape the
naked eye can be magnified so
they will be visible.
• Telescopes, borescopes, and
magnifying glasses aid in
performing visual inspection.
Dye Penetrant Inspection

• Penetrant inspection is a nondestructive test for defects open to the

surface in parts made of any nonporous material. It is used with
equal success on such metals as aluminum, magnesium, brass,
copper, cast iron, stainless steel, and titanium. It may also be used
on ceramics, plastics, molded rubber, and glass.
• Penetrant inspection will detect such defects as surface cracks or
porosity. These defects may be caused by fatigue cracks, shrinkage
cracks, shrinkage porosity, cold shuts, grinding and heat treat
cracks, seams, forging laps, and bursts. Penetrant inspection will
also indicate a lack of bond between joined metals.
• The main disadvantage of penetrant inspection is that the defect
must be open to the surface in order to let the penetrant get into the
defect. For this reason, if the part in question is made of material
which is magnetic, the use of magnetic particle inspection is
generally recommended.
Dye Penetrant Inspection _ cont’

• Penetrant inspection depends for its success upon a penetrating

liquid entering the surface opening and remaining in that opening,
making it clearly visible to the operator. It calls for visual
examination of the part after it has been processed, but the visibility
of the defect is increased so that it can be detected. Visibility of the
penetrating material is increased by the addition of dye which may
be either one or two types - visible or fluorescent.

• The visible penetrant kit consists of dye penetrant, dye remover

emulsifier and developer. The fluorescent penetrant inspection kit
contains a black light assembly as well as spray cans of penetrant,
cleaner, and developer. The light assembly consists of a power
transformer, a flexible power cable, and a hand held lamp. Due to its
size, the lamp may be used in almost any position or location.
DyeLiquid
PenetrantPenetrant
Inspection Inspection
• A liquid with high surface wetting characteristics
is applied to the surface of the part and allowed
time to seep into surface breaking defects.
• The excess liquid is removed from the surface
of the part.
• A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it
on the surface where it can be seen.
• Visual inspection is the final step in the
process. The penetrant used is often loaded
with a fluorescent dye and the inspection is
done under UV light to increase test
sensitivity.
Magnetic Particle Inspection
• Magnetic particle inspection is a method of detecting invisible
cracks and other defects in ferromagnetic materials, such as
iron and steel.
• This method of inspection is a nondestructive test, which
means it is performed on the actual part without damage to
the part. It is not applicable to nonmagnetic materials.
• In rapidly rotating, reciprocating, vibrating, and other highly
stressed aircraft parts, small defects often develop to the point
that they cause complete failure of the part.
• Magnetic particle inspection has proved extremely reliable for
the rapid detection of such defects located on or near the
surface.
• In using this method of inspection, the location of the defect is
indicated and the approximate size and shape are outlined.
Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are
then applied to the specimen. These particles are attracted to magnetic flux
leakage fields and will cluster to form an indication directly over the discontinuity.
This indication can be visually detected under proper lighting conditions.
Magnetic Particle Inspection

• If a discontinuity is present, the magnetic

lines of force will be disturbed and opposite
poles will exist on either side of the
discontinuity. The magnetized particles thus
form a pattern in the magnetic field between
the opposite poles. This pattern, known as
an "indication," assumes the approximate
shape of the surface projection of the
discontinuity.
• A discontinuity may be defined as an
interruption in the normal physical structure
or configuration of a part such as a crack,
forging lap, seam, inclusion, porosity, and
the like. A discontinuity may or may not
affect the usefulness of a part.
Magnetic Particle Inspection
• If a discontinuity is present, the
magnetic lines of force will be disturbed
and opposite poles will exist on either
side of the discontinuity. The
magnetized particles thus form a pattern
in the magnetic field between the
opposite poles. This pattern, known as
an "indication," assumes the
approximate shape of the surface
projection of the discontinuity.
• A discontinuity may be defined as an
interruption in the normal physical
structure or configuration of a part such
as a crack, forging lap, seam, inclusion,
porosity, and the like. A discontinuity
may or may not affect the usefulness of
a part.
Magnetic Particle Crack
Indications
Radiography

• X and gamma radiations, because of their unique ability

to penetrate material and disclose discontinuities, have
been applied to the radiographic (X-ray) inspection of
metal fabrications and nonmetallic products.
• The penetrating radiation is projected through the part to
be inspected and produces an invisible or latent image in
the film. When processed, the film becomes a
radiograph or shadow picture of the object. This
inspection medium, in a portable unit, provides a fast
and reliable means for checking the integrity of airframe
structures and engines.
RADIOGRAPHY
Radiography _ cont’

• Radiographic inspection techniques are used to locate

defects or flaws in airframe structures or engines with
little or no disassembly. This is in marked contrast to
other types of nondestructive testing, which usually
require removal, disassembly, and stripping of paint from
the suspected part before it can be inspected. Due to the
nature of X-ray, extensive training is required to become
a qualified radiographer, and only qualified radiographers
are allowed to operate the X-ray units.
• Three major steps in the X-ray process discussed in
subsequent paragraphs are: (1) Exposure to radiation,
including preparation, (2) processing of film, and (3)
interpretation of the radiograph.
 Radiography
The radiation used in radiography
testing is a higher energy (shorter
High Electrical Potential
wavelength) version of the
electromagnetic waves that we
see as visible light. The radiation can Electrons
come from an X-ray generator or a + -
radioactive source.
X-ray Generator
or Radioactive
Source Creates
Radiation

Radiation
Penetrate
the Sample

Exposure Recording Device

 Film Radiography
The part is placed between the
radiation source and a piece of film.
The part will stop some of the
radiation. Thicker and more dense
area will stop more of the radiation.
The film darkness
(density) will vary with
the amount of radiation
X-ray film reaching the film
through the test object.
= less exposure
= more exposure
Top view of developed film
Radiographic Images
Radiography _ cont’
Radiography _ cont’
Radiography _ cont’
Radiography _ cont’
Radiography _ cont’
Radiography _ cont’
Radiography _ cont’
Ultrasonic Testing
High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
f
showing the depth of features that reflect sound.

initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate

Oscilloscope, or flaw
detector screen
High resolution images can be produced by plotting
signal strength or time-of-flight using a computer-
controlled scanning system.

Gray scale image produced using Gray scale image produced using the
the sound reflected from the front sound reflected from the back surface
surface of the coin of the coin (inspected from “heads” side)
Ultrasonic Testing
• Ultrasonic detection equipment has made it
possible to locate defects in all types of
materials without damaging the material being
inspected. Minute cracks, checks, and voids,
too small to be seen by X-ray, are located by
ultrasonic inspection. An ultrasonic test
instrument requires access to only one surface
of the material to be inspected and can be
used with either straight line or angle beam
testing techniques.
• Two basic methods are used for ultrasonic
inspection. The first of these methods is
immersion testing. In this method of
inspection, the part under examination and the
search unit are totally immersed in a liquid
couplant, which may be water or any other
suitable fluid.
Ultrasonic Testing _ cont’

• The second method is called contact

testing, which is readily adapted to field
use. In this method the part under
examination and the search unit are
coupled with a viscous material, liquid or
a paste, which wets both the face of the
search unit and the material under
examination.

• There are two basic ultrasonic systems:

(1) Pulsed and (2) resonance. The pulsed
system may be either echo or through
transmission; the echo is the most
versatile of the two pulse systems.
Ultrasonic Testing _ cont’
Eddy Current Testing
• Electromagnetic analysis is a term
which describes the broad spectrum
of electronic test methods involving
the intersection of magnetic fields
and circulatory currents. The most
widely used technique is the eddy
current.
• Eddy currents are composed of free
electrons, which are made to "drift"
through metal, under the influence
of an induced electromagnetic field.
Eddy Current Testing

• Eddy current is used in aircraft

maintenance to inspect jet
engine turbine shaft and vanes,
wing skins, wheels, bolt holes,
and spark plug bores for
cracks, heat or frame damage.
In aircraft manufacturing plants,
eddy current is used to inspect
castings, stampings, machine
parts, forgings, and extrusions.
 Crash of United Flight 232
Sioux City, Iowa, July 19, 1989
A defect that went
undetected in an
engine disk was
responsible for
the crash of
United Flight 232.