TURKISH NATIONAL AEROSPACE NONDESTRUCTIVE TESTING BOARD

Transcription

1 Page No 1 / 40 TURKISH NATIONAL AEROSPACE (Document No: NANDTB-TR-002)

2 INDEX Page No 2 / 40 Cover Page Index List of Effective Pages History of Revisions Record of Temporary Revisions Page Definitions Abbreviations 1. Table of Contents 1.1. Penetrant Testing (PT) PT General page PT Specific page Magnetic Particle Testing (MT) MT General page MT Specific page Eddy Current Testing (ET) ET General page ET Specific page Ultrasonic Testing (UT) UT General page UT Specific page Radiographic Testing (RT) RT General page RT Specific page Thermographic Testing (TT) TT General page TT Specific page 40

3 Page No 3 / 40 LIST OF EFFECTIVE PAGES Page No. Issue / Revision No. Issue / 1/40 (Cover Page) /40 (Index) / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

4 Page No 4 / 40 HISTORY OF REVISIONS Revision No. Issue No. Issue / Revision Type Inserted by 00 Original M. İlker SUNAOĞLU Mustafa AKKAŞ

5 Page No 5 / 40 RECORD OF TEMPORARY REVISIONS PAGE Revision No. Edited/Amended Page(s) Effective Date Inserted by

6 1.1. Penetrant Testing (PT) TURKISH NATIONAL AEROSPACE Page No 6 / PT General PT - General (1/4) Surface tension Physical principles Wetting Capillarity Principles Penetrants Penetrant systems Remover Developer Classification of penetrants Precleaning Procedure Types of precleaning Abrasive Blast Mechanical precleaning Grinding, Sanding, Brushing Impact of the mechanical precleaning Removal of Material Smearing Impact on the figures after grinding Cleaning Impact on the figures after shotpeening Acid cleaning Watery degreasing Solvent Cleaning Chemical precleaning Vapour Degreasing Electrolytic cleaning Ultrasonic Cleaning Paint stripping agent

7 Page No 7 / 40 PT - General (2/4) Penetration procedure Penetrant removal Temperature requirements as per standards Penetrant application Wetting Dwell time Factors influencing penetrant dwell time Dipping time, drain time Factors influencing penetrant removal Water Lipophilic emulsifier Process of testing Viewing Drying Developing Radiation facilities Characteristic of human eye Solvent Hydrophilic remover Drying process after precleaning Drying process after penetrant removal Dry developer Water soluble developer Water suspended developer Solvent based developer Special developer Developer Dwell Comparison of Developers UV-A lamp Examination conditions Measuring tools for illumination and radiation Acuity performance Ability to discriminate colour Contrast sensitivity Brightness adaptation Astigmatism

8 Page No 8 / 40 PT - General (3/4) Selection of penetrant Control of penetrant characteristics Control of penetrant process Classification of penetrant Penetrant testing as per EN ISO Characteristics to be tested System performance check Additional testing of penetrant materials Very low Low Medium High Ultra high Sample test Batch testing Monitoring by the user Density Wetting/ marginal angles Viscosity Flashpoint Vapour pressure Colour Brightness Water tolerance Removability UV-Resistance Corrosive components Characteristics of developer Reference test block EN ISO PSM star burst panel Storage of reference test block Inspection booth checks Surface wetting test Penetrant rapid brightness test Lipophilic emulsifier removability test Hydrophilic remover refractometer test Hydrophilic remover hydrometer test

9 Page No 9 / 40 Control of penetrant process Evaluation and reporting of testing instructions Safety Quality assessment PT - General (4/4) Additional testing of penetrant materials Detectable defects on different materials Product related risks UV-related risks Environmental waste water management Procedures and standards Construction concept Comparison to other NDT methods Documentation Personnel requirements Remover quick test for penetrant contamination Hydrophilic remover performance check Dry developer contamination test Water-suspended developer concentration test Water pressure and temperature check Measurement of black light intensity Related and non-related indication Inspection of non-metallic material Inspection of ceramic materials Inspection of composite National and international standards Safe live Fail safe Damage tolerance Limits of PT inspections Detectable flaw size Other NDT procedures Issue of inspection procedures Inspection reports

10 PT Specific TURKISH NATIONAL AEROSPACE Page No 10 / 40 PT - Specific Airframe Engine Components & Reworked parts Crack and corrosion detection in Crack detection in Crack detection in Fittings and lugs Bolts Landing gear Rods Links Structure Skin Pins Gears Mounts Bolts Shafts Cases Blades Discs Slots Bores Wheels Pins Gears Mounts Bolts Shafts Cases Blades Discs Slots Bores

11 1.2. Magnetic Particle Testing (MT) TURKISH NATIONAL AEROSPACE Page No 11 / MT General Basic Principles MT - General (1/5) Volt Current Frequency Electrical resistance Phase Electrical parameters Electrical resistance Effect of electrical current Ohm's Law Circuit diagrams Direct current Alternating current Physical principles of magnetic particle inspection Ferromagnetism Magnetic fields Magnetic lines of force Magnetic field strength Magnetical parameters Permeability Magnetic flux Magnetic flux density Hysteresis Required field strength Electromagnetic induction Magnetic fields on electrical conductors Ferromagnetic materials in magnetic fields Transformation Skin effect Field strength Flux density in and around electrical conductors

12 Page No 12 / 40 Physical principles of magnetic particle inspection Magnetisation MT - General (2/5) Evidence of adequate field strength Combined procedures Demagnetisation Principles of magnetisation technique Hall-effect gauss meter Combination of two constant magnetic fields Combination of constant and alternating magnetic fields Combination of two alternating magnetic fields Phase shifted alternating magnetic fields Field Direction Field strength Magnetic field orientation and flaw Detectability Yoke magnetisation Coil magnetisation Circular magnetisation with prods Circular magnetisation with direct contact Circular magnetisation with induced current Circular magnetic fields distribution and intensity Current amperage for the direct contact Longitudinal magnetisation Cable wrap technique Current amperage for the longitudinal magnetisation Method of current application Continuous application technique Residual application technique Combined techniques

13 Page No 13 / 40 MT - General (3/5) Portable equipment Equipment Stationary equipment Demagnetisation coils Wet-Bath method Dry particles Testing equipment and utilities Procedure monitoring Test products Test blocks and tools Tangential field strength measurement Radiation facilities Illumination and radiation measurement Dry method vs. wet method Fluorescent and coloured test products Visible particles vs. fluorescent particles Preparation of testing suspension Test block for systems performance Test block for equipment performance Field strength measuring instrument Field indicators Hall-effect (gauss/tesla) meter Quantitative quality indicator Pie gage Berthold test block Test block for magnetisation control UV-A lamp Examination conditions Measuring tools for illumination and radiation UV-A radiation measurement White light measurement

14 Page No 14 / 40 MT - General (4/5) Viewing Evaluationand reportingoftesting instructions Material science Characteristic of human eye Evaluation Assessment Producing an indication Interpreting the indication Evaluating the indication Non-relevant indications Magnetic writing Cold working Abrupt changes of section Elimination of non-relevant indications Inspection protocol Structure of inspection procedure Case studies Standards Inspection instructions Company internal regulations Defects during manufacturing process Acuity performance Ability to discriminate colour Contrast sensitivity Brightness adaptation Astigmatism Inclusion Porosity Cracks Pipe Blowholes Segregation

15 Page No 15 / 40 Material science Safety Process Control Quality assessment MT - General (5/5) Defects during machining process Flaws through operation Electrical hazards Product related risks UV-related risks General description System effectiveness check Ammeter check Quick break test Dead weight check Particle concentration test Particle contamination tests Lighting requirements Construction concept Comparison to other NDT methods Documentation Personnel requirements Roll and forging flaws Turning and grinding flaws Flaws through hardening process Cracks Corrosion Safe live Fail safe Damage tolerance Limits of MT inspections Detectable flaw size Other NDT procedures National and international standards Issue of inspection procedures

16 MT Specific TURKISH NATIONAL AEROSPACE Page No 16 / 40 MT - Specific Airframe Engine Components & Reworked parts Crack and corrosion detection in Crack detection in Crack detection in Fittings and lugs Bolts Landing gear Rods Links Pins Gears Mounts Bolts Shafts Cases Tubes Welded parts Bolts Gears Shafts Cases

17 1.3. Eddy Current Testing (ET) TURKISH NATIONAL AEROSPACE Page No 17 / ET General ET - General (1/4) Direct current; current and voltage Resistance Conductance Ohm's law Resistivity Conductivity Electricity Conductivity values for some metals Alternating current; sinusoidal current and voltage Amplitude Frequency Period Physic and fundamentals of eddy current Phase Vector representation Other periodic currents Magnetic field Lines of force Magnetic field strength Permeability Flux density (Induction) Magnetism Flux, hysteresis loop Reluctance Magneto-motive force Diamagnetism Paramagnetism Ferromagnetism

18 Page No 18 / 40 ET - General (2/4) Magnetic field created by a current (wire, coil) Electromagnetic induction phenomenon Inductance Physic and fundamentals of eddy current Electromagnetism Impedance plane diagrams Self inductance Inductive reactance Mutual induction Electromagnetic coupling Induced currents and secondary field Lenz s law Eddy current distribution in conducting materials Planar wave; standard depth of penetration Amplitude, phase Cylindrical conductors; characteristic frequency Skin effect Penetration depth Impedance Complex plane representation Influence of conductivity Influence of frequency Influence of permeability Influence of probe clearance Influence of thickness Influence of an on-conductive coating on conductive material Influence of a through defect Influence of internal defects

19 Page No 19 / 40 Eddy current equipment Eddy current applications ET - General (3/4) ET Probes ET instruments Reference standards ET Testing Design of probes (Mechanical and electrical) Operation of probes (Absolute, differential) Use of probes (Pencil, borehole, sliding, etc.) Connections of probes with ET unit Display modes; needle, digital display Instrument modules Operating principle Signal excitation, reception, processing Compensation Wheatstone bridge Filtering; LPF, HPF, BPF Single frequency Multi frequency Design Production Storage Difference to real defects Conductivity Material sorting Overheat damage Material identification Thickness of an on-conductive coating on conductive material Influence of temperature Influence of inspection speed Manual inspections Automated inspections External influence during ET testing Crack inspection

20 Page No 20 / 40 Eddy current applications Quality assessment ET Testing ET - General (4/4) Construction concept Comparison to other NDT methods Procedures and standards Documentation Personnel requirements Corrosion inspection Sliding probes Array applications Safe live Fail safe Damage tolerance Limits of ET inspections Detectable flaw size Other NDT procedures National and international standards Issue of inspection procedures Inspection reports ET Specific Airframe Paint thickness measurement Cracks ET - Specific (1/2) Material Characteristics On metallic structure Surface (HFEC) Subsurface (LFEC) Array applications Cracks in multilayered structure Cracks in riveted structure Bolthole Conductivity Material sorting Overheat damage Material identification

21 Page No 21 / 40 ET - Specific (2/2) Single layer Corrosion detection Multilayered structure Boltholes Airframe Engine Components Crack and discontinuous detection in Crack detection in Crack detection in Conductivity Array applications Fittings and lugs Fastener holes Riveted structures Bolts Tubes Multilayered structure Welded structure Wrought materials Forged materials Blades High energy rotating hardware (disc, shafts, blade slots) Stators Welded parts Wrought materials Forged materials Cast materials Automated systems Wheels Tubes Welded parts Bolts Gears Automated systems Heat treatment Overheat damage

22 1.4. Ultrasonic Testing (UT) TURKISH NATIONAL AEROSPACE Page No 22 / UT General Basic principles of acoustics Generation of UT-waves Propagation of UT-waves Mathematic basics UT - General (1/5) Frequency, velocity and wavelength Different acoustic waves Generation Characteristics of search units Sound beam Ultrasonic equipment Acoustic impedance Reflection/Transmission Phase inversion Angle beam Refraction Wave transformation Critical angle Long-waves Shear-waves Surface-waves Plate-waves Piezoelectricity and types of crystals Frequency-crystal thickness relationships Conversion efficiencies of various crystals Construction of ultrasonic search units Damping and resolution Sound beam characteristics Beam intensity characteristics Broadband/Small band signal Beam divergence Near and far zones Attenuation Impulse form and repetitions Frequency

23 Page No 23 / 40 Propagation of UT-waves UT - General (2/5) Wave propagation in material and gas Wave propagation in liquids Contact testing Immersion testing Through transmission UT methods Pulse-echo Dual transducer Angle beam Phased arrays Analogue Equipment Digital Phased array (PAUT) UT Systems Displays Transducer Wedges Couplants Reference standards Cables A-scan B-scan C-scan D-scan Sector-scan Thickness gages Straight beam transducers Dual transducers Angle beam transducer Phased array transducers Focused transducers Standardized reference standards Specific reference standards

24 Page No 24 / 40 UT - General (3/5) Surface roughness Concave/Convex surfaces Influence of surface/geometry Object geometry Wave transformation Triangle reflection Influence of part Angle reflection Sound absorption Influence of material properties Acoustic noise Diffusion Signal to noise ratio (SNR) Improvement of SNR Flat bottom holes Cross holes Groove Artificial defects Ball reflector Variation of sound distance Variation of artificial defect Calibration Different defects Calibration standards Sensitivity Calibration and functional tests Depth compensation Functional tests Evaluation Evaluation of indication Analysis of probe data Redundancy checks Display indications (True/false) Defects dependency Location of defects Depth of defects Half-value methods

25 Page No 25 / 40 UT - General (4/5) Evaluation Quality assessment UT applications Evaluation of indication Construction concept Comparison to other NDT methods Procedures and standards Documentation Personnel requirements Castings Forgings Bars Rolled sheet and plate Testing pipe and tubing Welds Determining discontinuity location Thickness measurement Use of shear wave Use of surface waves (Rayleigh waves) Loss of back wall signal Composition with artificial defects Evaluation with tables Detectable flaw size Discontinuity orientation Discontinuity spacing Types of discontinuity indications Delaminations Safe live Fail safe Damage tolerance Limits of UT inspections Detectable flaw size Other NDT procedures National and international standards Issue of inspection procedures Inspection reports

26 Page No 26 / 40 UT applications UT - General (5/5) Use of plate waves (Lamb waves) Needs for process controls Vertical linearity Inspection system sensitivity check System (Equipment) checks Horizontal linearity Ultrasonic inspection process controls Entry surface resolution Back surface resolution Angle beam point-of-incidence Angle Beam Checks Angle beam point-of-incidence Angle beam angle determination Angle beam misalignment

27 UT Specific TURKISH NATIONAL AEROSPACE Page No 27 / 40 UT - Specific (1/2) Corrosion measurement Thickness measurement Wall thickness measurement On metallic structure On composite structure CFRP Airframe Engine Delamination Water ingress in honeycomb structures Debonding Imperfections in composites Crack and discontinuous detection in Crack detection in GFRP Glare Honeycomb structure Glare Metallic structure Blowholes Porosity Inclusions Fittings and lugs Fastener holes Riveted structures Bolts Tubes Multilayered structure Welded structure Wrought materials Forged materials Other applications (glass, plastics) Blades High energy rotating hard ware (disc, shafts, blade slots) Stators

28 Page No 28 / 40 UT - Specific (2/2) Engine Composite Components Crack detection in Thickness measurements Delamination Delamination Water ingress in honeycomb structures Debonding Imperfections in composites Crack detection in Delamination Water ingress in honeycomb structures Debonding Imperfections in composites Welded parts Wrought materials Forged materials Cast materials Composite blades CFRP GFRP Glare Honeycomb structure Clare Blowholes Porosity Inclusions Wheels Tubes Welded parts Bolts Gears CFRP GFRP Glare Honeycomb structure Clare Blowholes Porosity Inclusions

29 1.5. Radiographic Testing (RT) TURKISH NATIONAL AEROSPACE Page No 29 / RT General RT - General (1/9) History Philosophy Capabilities Introduction Process of radiography Types of electromagnetic radiation sources Electromagnetic spectrum Penetration ability or quality of x-rays and gamma rays X-ray tube Theory, Physics Principles of radiography X-rays generation Gammagraph Electromagnetic spectrum Significance of wavelength Theory, physics Characteristics and key properties Interaction; absorption and scatter Nature and properties of x-rays Interaction x-rays/materials X-rays absorption, attenuation coefficient Radiography principle Generation principles, spectrum of radiation X-ray tubes up-to 420kV X-rays accelerator Energy spectra Isotope source strength Isotope source focal spot size Isotope source decay characteristics Isotope source sensitivity

30 Page No 30 / 40 RT - General (2/9) Energy and equivalent energy Gammagraph Isotope requirements Characteristics and merits of isotopes Half-value layer Rectilinear propagation Affecting factors Image formation Inverse square law consideration Types and choice of film Theory, Physics Types and uses of screens Radiation quality Effect of changing kv Significance and effect of type of x-ray source Effect of time Radiographic film Milliamperage and FFD on exposure Exposure charts Identification, marking out and sitting up Intensifying screens role and use Filters X-ray machine Equipment Exposure techniques Types of equipment Auxiliary equipment General principles Selection of equipment X-ray control panel Isotope equipment Contrast; object, image, average gradient Radiation energy

31 Page No 31 / 40 RT - General (3/9) Focal-spot size Determination of focal spot size Exposure parameters determination RT-techniques, with constant exposure Defects position, triangulation Exposure Enlargement and projection Contrast Exposure techniques Single-wall radiography Double-wall radiography Multiple-film techniques Penetrameters or image quality indicators (IQI s) Object, image, average gradient Radiation energy Scattered radiation, limitations Source-to-film distance Heel effect Specimen configuration Double-wall exposure, single-wall viewing Offset double-wall exposure, single-wall viewing Elliptical projections Panoramic radiography Specimen configuration Discontinuity location radiographic configurations Use of multiple-film loading Thickness-variation parameters Film speed Film latitude Types of penetrameters or IQI s Use rules Standards Calculation of IQI sensitivity

32 Page No 32 / 40 RT - General (4/9) Shadow formation and distortion Geometric exposure principles Shadow enlargement calculation Shadow sharpness Geometric unsharpness Basic principles Scattered radiation, limitations Lead intensifying screens Radiographic screens Fluorescent intensifying screens Intensifying factors Importance of screen-to film contact Radiographs Radiographic image quality Darkroom facilities, film processing General Arithmetic of radiographic exposure Radiographic sensitivity Radiographic contrast Film contrast Subject contrast Film graininess and screen mottle effects Penetrameters or imagequality indicators Improving radiographic sensitivity Photographic emulsion chemistry Facilities and equipment Film packing Film material and classification systems Formation of the latent image on film Inherent unsharpness Milliamperage-distance-time relationship Reciprocity law Photographic density Inverse-square-law considerations Automatic film processor versus manual processing

33 Page No 33 / 40 RT - General (5/9) Developer and replenishment Stopbath Fixer and replenishment Processing of film-manual Washing Darkroom facilities, film processing Digital radiography Film filing and storage Unsatisfactory radiographscauses and cures Film density Basic image types Analogue versus digital images Digital image quality Pixel depth Capture Digital image quality factors Prevention of water spots Drying Temperature control Retention-life measurements Long-term storage Filing and separation techniques High film density Insufficient film density High contrast Low contrast Poor definition Fog Light leaks Handling faults, artifacts Step-wedge comparison film Densitometers Film based capture Filmless capture Noise Dynamic range Artifacts

34 Page No 34 / 40 RT - General (6/9) Scope Ventilation in darkroom Safelights Why test safelights Process controls Forgings, castings Assemblies, welding, brazing, riveting Composite materials Individual safelight testing Collective safelight testing Safelight fog evaluation Controlling the manual development process Controlling the automatic development process Metallurgy knowledge and manufacturing techniques Defectsmet Application of standards Welding processes Defectsmet Application of standards Welding NDT inspection Concepts of development Defectsmet Application of standards Cavities, gasholes, shrinkage, foreign material Castings NDT inspection NDT technique instructions Shooting use of the IQI and interpretation/evaluation Disposition and NDT report Cracks, lack of penetration or brazing, inclusions Examination of circumferential in pipes welding/butt-welds NDT technique instructions Disposition and NDT report Cavities

35 Page No 35 / 40 RT - General (7/9) Composite materials Indications, discontinuities and defects Manufacturing processes and associated discontinuities Evaluation Composite NDT inspection Indications Discontinuities Defects Casting processes and associated discontinuities Wrought processes and associated discontinuities Welding processes and associated discontinuities Radiographic standards Radiographic viewing Tangential shooting NDT technique instructions Shooting use of the IQI and interpretation/evaluation Disposition and NDT report Adventitious images Causes and effects Inherent Processing Service Ingots, bloomsand billets Sand casting Centrifugal casting Investment casting Forgings Rolled products Extruded products Submerged arc welding Shielded metal arc welding Gas metal arc welding Flux corded arc welding Gas tungsten arc welding Film-illuminator requirements Background lighting Multiple-composite viewing Penetrameter placement Personnel dark adaptation and visual acuity

36 Page No 36 / 40 RT - General (8/9) Film identification Location markers Radiographic viewing Film-density measurement Film artifacts Evaluation Safety Quality assessment Evaluation of casting images Evaluation of welding images Radiation safety principles Standards, codes and procedures for radiography Viewing conditions Illuminator requirements Casting-method review Casting discontinuities Origin and typical orientation of discontinuities Radiographic appearance Castings codes/standards-applicable acceptance criteria Reference radiographs Welding-method review Welding discontinuities Origin and typical orientation of discontinuities Radiographic appearance Welding codes/standards-applicable Acceptance criteria Reference radiographs or pictograms Controlling personnel exposure Time, distance, shielding concepts ALARA concepts Radiation-device operation characteristics Acceptable radiographic techniques and setups Applicable employer procedures Procedure for radiograph parameter verification Radiographic reports

37 Page No 37 / 40 RT - General (9/9) Safe live Construction concept Fail safe Quality assessment Comparison to other NDT methods Documentation Personnel requirements Damage tolerance Limits of RT inspections Detectable flaw size Other NDT procedures Issue of inspection procedures Inspection reports RT Specific Airframe Engine RT - Specific (1/2) Water ingress in honeycomb structures Imperfections in composites Crack and corrosion, porosity detection in Crack detection in Blowholes Porosity Inclusions Fittings and lugs Fastener holes Riveted structures Bolts Tubes Multilayered structure Welded structure Wrought materials Forged materials Blades Stators Welded parts

38 Page No 38 / 40 Engine Composites Components Crack detection in General overview RT - Specific (2/2) Water ingress in honeycomb structures Imperfections in composites Crack detection in Water ingress in honeycomb structures Imperfections in composites Wrought materials Forged materials Cast materials Foreign objects Blocked gas passes Misalignments of parts Blowholes Porosity Inclusions Layer orientation Distribution of glass fibers Tubes Welded parts Bolts Blowholes Porosity Inclusions Foreign objects Blocked gas passes Misalignments of parts

39 1.6. Thermographic Testing (TT) TURKISH NATIONAL AEROSPACE Page No 39 / TT General TT - General Fundamentals of Thermography Principles Qualitative imagery Quantitative thermography Heat transfer theory Thermal radiation principles Transmittance Applications Safety Quality assessment Infrared Thermography Thermography safety principles Standards, codes and procedures for thermography Construction concept Comparison to other NDT methods Documentation Personnel requirements Equipment overview Basic camera setup and operation Thermal measurement Moisture detection in honeycomb Heater blanket and hot air gun methods as outlined by producer Defining difference between excessive resin and fluid ingress Acceptable thermographic techniques and setups Applicable employer procedures Procedure for thermograph parameter verification Thermographic reports Safe live Fail safe Damage tolerance Limits of TT inspections Detectable flaw size Other NDT procedures Issue of inspection procedures Inspection reports

40 TT Specific TURKISH NATIONAL AEROSPACE Page No 40 / 40 Composites TT - Specific Water ingress in honeycomb structures Imperfections in composites Blowholes Porosity Inclusions Layer orientation Distribution of glass fibers