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NDT Application in Aircraft Industry / Human Faktor Effect

NDT Application in Aircraft Industry / Human Faktor Effect. Short personal introduction Name : Jiří brus Date of Birth : 1962 NDT carier start : 1985 Actual NDT qualification : LII EN 473 VT, PT, MT, UT, RT, ET LII EN 4179/NAS 410

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NDT Application in Aircraft Industry / Human Faktor Effect

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  1. NDT Application in Aircraft Industry / Human Faktor Effect • Short personal introduction • Name : Jiří brus • Date of Birth : 1962 • NDT carier start : 1985 • Actual NDT qualification : • LII EN 473 • VT, PT, MT, UT, RT, ET • LII EN 4179/NAS 410 • VT, PT, MT, UT, RT, ET • LIII EN 4179/NAS 410 • VT, PT, MT, UT, RT, ET • Actual positions • Director and owner accredited NDT laboratory No. 1400 • Head of Job Air NDT Center • Outsite NDT L III servis for : - Technical laboratory TLO OPAVA - UNEX Uničov a.s. - Aircraft Industry LET Kunovice

  2. NDT Application in Aircraft Industry / Human Faktor Effect

  3. NDT Application in Aircraft Industry / Human Faktor Effect Why this subject ? Human error has been documented as a primary contributor to more than 70 percent of commercial airplane accidents. Boeing human factors professionals work with engineers, pilots, and mechanics to apply the latest knowledge about the interface between human performance and commercial airplanes to help operators improve safety and efficiency in their daily operations. General Content • Subject introduction • Aircraft mechanic / NDT mechanic • Applicable NDT methodes • VT methode application Direct visual inspection VS boroscopy • PT methode application Different qualification request • UT-T thickness measurement Nominal thickness knowlege necessity • MT methode Residual magnetizm check • ET methode Indirect influence to IACS value • Conclusion • Recomendation

  4. NDT Application in Aircraft Industry / Human Faktor Effect Aircraft mechanics Somebody who is higly trained and educated - Aircraft structure • Aircraft parts maintenance and check Knowlege from NDT area during the job practice and cooperation with NDT technician Human faktor training necessary. NDT mechanics Somebody who is higly trained and educated • Applicable NDT methodes • Sensitivity and test condition check Knowlege from maitainance area during the job practice and cooperation with B1 technician Human faktor training necessary

  5. NDT Application in Aircraft Industry / Human Faktor Effect • VISUAL INSPECTION METHODE • Human faktor effect – responsibility take-over (during boroscopy inspection instead direct visual inspection specified area) • Example 1 Official NDT request Airbus NTM 57-20-50 • Responsibility on NDT in full because NTM include – procedure - inspection area specification - possible damage specification

  6. NDT Application in Aircraft Industry / Human Faktor Effect • VISUAL INSPECTION METHODE • Official acces panels • Drain holes

  7. NDT Application in Aircraft Industry / Human Faktor Effect • VISUAL INSPECTION METHODE • Human faktor effect – responsibility take-over (during boroscopy inspection instead direct visual inspection specified area) • Example 2 Official Task Card request : • Perform general visual inspection of the zone IAW TC 5711-622-80I - All components will be ispected for : Security of attachements, visible connections, electrical bonding, safety wiring, leakage, cracks, corrosion, chafing, evidence of overheating, condition of painting and corrosion treatment and cleanlines.

  8. NDT Application in Aircraft Industry / Human Faktor Effect • VISUAL INSPECTION METHODE • Example 2 : • Responsibility on B1 in full because - there is not NDT procedure - there is not request for NDT qualification Remark: EWIS training - Electrical Wiring Interconnection Systém NDT person probably will be not trainined for connection, electrical bonding , safety wiring…etc.

  9. NDT Application in Aircraft Industry / Human Faktor Effect • PENETRANT TESTING METHODE • Human faktor effect – qualification and type application understanding (many confliction request comparing part 145 / AC manual) • Example Part 145 EASA is speaking about colour penetrant testing wchich means in fakt Type 2 acc. ASTM E1417.

  10. NDT Application in Aircraft Industry / Human Faktor Effect • PENETRANT TESTING METHODE • NDT Manual request • SAAB • NDT 51-08-00 • Type 2, Not used for fatigue cracks or tight defects • Boeing • NDT 20-20-02 • Type 2, Inspection of ground handling or support equipment, tools and tooling only. • AIRBUS • NDM 51-80-00 • For general use on aircraft in-service inspections the following penetrants are recommended: • (1) Type I, Method C, Level 2, 3 or 4 (Solvent removable, fluorescent).

  11. NDT Application in Aircraft Industry / Human Faktor Effect • PENETRANT TESTING METHODE • Final „Only Option“ = FPI application • Test condition check – time / temperature / PSM5 / UV-light / day-light • Right type application / sensitivity 2, 3, 4 ? ? ?

  12. NDT Application in Aircraft Industry / Human Faktor Effect • PENETRANT TESTING METHODE • Personal qualification request – for information only

  13. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK • Human faktor effect – technique and equipment adequate to test request (nominal thickness proficiency)

  14. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK • Human faktor effect – technique and equipment adequate to test request (nominal thickness proficiency) • 1. step / to choose right equipment and see right echo

  15. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK • Human faktor effect – technique and equipment adequate to test request (nominal thickness proficiency) • 2. step / right probe and right equipment setting • Thickness reading for probe MSEB4 using 1. back wall echo If reading will be done from 3rd peak instead 2nd peak – difference is +0,37mm Because : λ = cL / f = 5,92 / 4 = 1,48 mm λ / 4peaks = 1,48 / 4 = 0,37 mm For us – Al mat. and 12 MHz probe = (6,32 / 12 / 4 = 0,131mm)

  16. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK (nominal thickness proficiency)

  17. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK (nominal thickness proficiency)

  18. NDT Application in Aircraft Industry / Human Faktor Effect • ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK (nominal thickness proficiency) • IAW SRM (Standard Repair Manual) we have to check fuselage thickness for change of 10% of nominal thickness, wchich can be in many cases about 1,00 mm. So the maximum blending allowed is to 0,10 mm. • Compare: REQUEST VS ACCURACY 0,10 mm 0,131 mm

  19. NDT Application in Aircraft Industry / Human Faktor Effect • MAGNETIC PARTRICLE TESTING METHODE • Human faktor effect – unexpected residual magnetism (unallowable on engine parts and others) • Request - magnetic particle inspection (using coil and/or central conductor)

  20. NDT Application in Aircraft Industry / Human Faktor Effect • MAGNETIC PARTRICLE TESTING METHODE • Human faktor effect – unexpected residual magnetism (unallowable on engine parts and others) Easy task – engin shaft magnetizing in coil using alternating current

  21. NDT Application in Aircraft Industry / Human Faktor Effect • MAGNETIC PARTRICLE TESTING METHODE • Human faktor effect – unexpected residual magnetism (unallowable on engine parts and others)

  22. NDT Application in Aircraft Industry / Human Faktor Effect • EDDY CURRENT TESTING METHODE • Human faktor effect – optainable accuracy during measuring (strong manual request for evaluation) Example – BOEING NTM Part 6 51-00-00 Procedure 20 Equipment…. • (d) Can clearly identify conductivity changes of 0.5 percent IACS (0.3 MS/m) in the applicable conductivity range. • (e) Can measure the conductivity of the applicable reference standards with a precision of plus or minus 0.5 percent IACS (0.3 MS/m) better.

  23. NDT Application in Aircraft Industry / Human Faktor Effect • EDDY CURRENT TESTING METHODE • Human faktor effect – optainable accuracy during measuring (strong manual request for evaluation) 1 temperature – effect, calibration standard (IACS 29,88%) measuring in 5 min

  24. NDT Application in Aircraft Industry / Human Faktor Effect • EDDY CURRENT TESTING METHODE • Human faktor effect – optainable accuracy during measuring (strong manual request for evaluation) Example – BOEING NTM Part 6 51-00-00 Procedure 20 IACS value for some alloys ….

  25. NDT Application in Aircraft Industry / Human Faktor Effect • EDDY CURRENT TESTING METHODE • Human faktor effect – optainable accuracy during measuring (strong manual request for evaluation) !! Warning !! There are six factors which affect the accuracy of eddy current conductivity measurements. These are : 1 temperature, 2 lift-off, 3 curved surfaces, Before you officially record change 1% IACS 4 edge effect, make shure you make all value correction 5 materials thickness, and you consider all factors. 6 and cladding as well

  26. NDT Application in Aircraft Industry / Human Faktor Effect „Easy?“ Conclusion VT methode Alwaysmakesureyouknow, what are youlookingfor ! PTmethod Rememberaircraftproducerdifferentstand to personal qualification and think about rigt penetrant type and sensitivity application ! UT-T method Recordedthicknesscomparewithdrawingand/ordocumentationbeforefinal evaluation MTmethod Even use alternatingcurrentalwayscheckresidualmagnetismand use demagnetizing coil in any case ! ETmethod Considerallindirect influence to recordedIACS value before you make final decision !

  27. NDT Application in Aircraft Industry / Human Faktor Effect • RECOMMENDATION • Acording to an old practis the certyfied aircraf mechanic must attend to first fly after aircraft servicing. • Remember you can use in future an aircraft you personally checked. • I wish you only safety fly with happy comeback. Thank you for your attention.

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