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Chinook Boeing CH-47D technical manual vol 7 Nondestructive test

Chinook Boeing CH-47D technical manual

Volume 7

General aircraft maintenance manual

Nondestructive testing and flaw detection

68 pages

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CHAPTER 1 INTRODUCTION ..................................................................................................... 1-1

CHAPTER 2 GENERAL ............................................................................................................... 2-1

CHAPTER 3 PENETRANT INSPECTIONS .................................................................................. 3-1

CHAPTER 4 MAGNETIC PARTICLE INSPECTIONS ................................................................... 4-1

CHAPTER 5 RADIOGRAPHY ...................................................................................................... 5-1

CHAPTER 6 ULTRASONIC INSPECTIONS.................................................................................. 6-1

CHAPTER 7 ELECTROMAGNETIC INSPECTIONS .................................................................... 7-1

APPENDIX A REFERENCES ........................................................................................................ A-1

GLOSSARY ............................................................................................................................Glossary-1

INDEX ............................................................................................................................ Index-1

INDEX
Subject Paragraph,
Figure, Table
Number
A
Advantages (of Radiography)........................................................................................................ 5-3
Advantages (of Ultrasonic Inspection) . ......................................................................................... 6-2
Amperage (Circular Magnetization) ............................................................................................... 4-9b
Amperage (Longitudinal Magnetization) ....................................................................................... 4-10b
Angle Beam Method ..................................................................................................................... 6-9b
Application, Field ......................................................................................................................... 7-4
Application of Cleaner .................................................................................................................. 3-14b
Application of Developer .............................................................................................................. 3-14e
Applications (of Longitudinal Magnetization) ................................................................................. 4-10c
Applications (of Radiography) ...................................................................................................... 5-5
Applying Transparent Tape ........................................................................................................... 4-12b
Availability of Penetrants .............................................................................................................. 3-8b
B
Basic Principles of Penetrant Inspection........................................................................................ 3-3
Basic Terminology (of Magnetism) ................................................................................................ 4-3
Ferromagnetic Metals . ........................................................................................................... 4-3a
Leakage Field. ........................................................................................................................ 4-3b
Magnetic Substances ............................................................................................................. 4-3d
Magnetic Flux ......................................................................................................................... 4-3e
Magnetism............................................................................................................................. 4-3c
Permeability........................................................................................................................... 4-3f
Residual Magnetism . ............................................................................................................. 4-3g
Retentivity ............................................................................................................................. 4-3h
Basic Testing Methods (Ultrasonics).............................................................................................. 6-4
Beam Divergence ......................................................................................................................... 6-7c
Best Access to Object ................................................................................................................... 5-6f
Black Light . ................................................................................................................................. 3-11d
C
Calibration of Ultrasonic Equipment .............................................................................................. 6-10
Capabilities and Limitations (Magnetic Particle Inspection)............................................................ 4-5
Changing Magnitude of Current..................................................................................................... 7-5c
Characteristics, Transmission........................................................................................................ 6-7
Circular Magnetization ................................................................................................................. 4-9
Amperage .............................................................................................................................. 4-9b
Technique.............................................................................................................................. 4-9a
Compatibility ............................................................................................................................... 3-8a
Conditions Not Requiring Demagnetization ................................................................................... 4-13b
Consumable Materials .................................................................................................................. 1-3
Continuous Method. ...................................................................................................................... 4-8b
Couplants .................................................................................................................................... 6-8d
Index
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
C - Continued
Current and Particle Application ................................................................................................... 4-8
Continuous Method ................................................................................................................ 4-8b
Field Direction ........................................................................................................................ 4-8c
Field Measurement ................................................................................................................. 4-8d
Residual Method .................................................................................................................... 4-8a
Sensitivity Level ..................................................................................................................... 4-8e
Currents, Eddy ............................................................................................................................. 7-3
D
Data, Use of ................................................................................................................................ 2-6
Defects, Honeycomb, Fiberglass, and Composite ......................................................................... T2-2
Definitions (Magnetic Particle Inspection Terms) .......................................................................... 4-11a
Degree of Sensitivity .................................................................................................................... 5-6d
Demagnetization . ......................................................................................................................... 4-13
Conditions Not Requiring Demagnetization ............................................................................ 4-13b
Limits of Demagnetization ...................................................................................................... 4-1 3d
Reasons for Demagnetization . ............................................................................................... 4-13a
Techniques for Demagnetization ............................................................................................ 4-1 3a
Destructive Tests ......................................................................................................................... 2-4a
Detection Standards (Radiation) ................................................................................................... T5-1
Detection, Flaw ............................................................................................................................. 2-7, T2-1
Developer Application ................................................................................................................... 3-10j
Developer Draining ...................................................................................................................... 3-10k
Developer Dwell Time................................................................................................................... 3-101
Disadvantages (of Radiography) .................................................................................................. 5-4
Disadvantages (of Ultrasonic Inspection) ...................................................................................... 6-3
Draining ....................................................................................................................................... 3-e
Dry Particle Indications ................................................................................................................. 4-12c
Drying .......................................................................................................................................... 3-c
E
Eddy Current Inspection, Uses of . ................................................................................................ T7-1
Eddy Current Test Set Model ED-520 ........................................................................................... 7-5
Changing Magnitude of Current ............................................................................................. 7-5c
Needle Defections .................................................................................................................. 7-d
Operation ............................................................................................................................... 7-5a
Testing Procedure .................................................................................................................. 7-5b
Eddy Currents .............................................................................................................................. 7-3
Electrical Precautions ................................................................................................................... 5-11d
Electromagnetic Inspections, General .......................................................................................... 7-1
Emulsifier Application ................................................................................................................... 3-10g
Emulsifier Draining ....................................................................................................................... 3-10h
Index 2
INDEX -CONT
Subject Paragraph,
Figure, Table
Number
E - Continued
Emulsifier Dwell Time .................................................................................................................. 3-10i
Equipment (Longitudinal Magnetization) ....................................................................................... 4-10d
Evaluate Discontinuity .................................................................................................................. 3-149
Exposure ..................................................................................................................................... 5-8a
Exposure and Processing, Film .................................................................................................... 5-8
Exposure Limits ........................................................................................................................... 5-11 b
F
Ferromagnetic Metals . ................................................................................................................. 4-3a
Field Application .......................................................................................................................... 7-4
Field Direction .............................................................................................................................. 4-8c
Field Measurement . ..................................................................................................................... 4-8d
Filing Radiographs . ...................................................................................................................... 5-10
Film Exposure and Processing ..................................................................................................... 5-8
Exposure ............................................................................................................................... 5-8a
Processing ............................................................................................................................. 5-8b
Film Placement ............................................................................................................................ 5-6b
Film Processing, Manual . ............................................................................................................. F5-1
Fixing Indications with Lacquer . ................................................................................................... 4-12a
Flaw Detection ............................................................................................................................. 2-7, T21
Fluorescent Indications ................................................................................................................ 4-12e
Fluorescent Penetrant Inspection, Specific Procedures for ............................................................ 3-11
Fluorescent Penetrant Processes .................................................................................................. 3-13
Fluoroscopy . ............................................................................................................................... 5-7a
Fundamentals of Magnetic Particle Inspection ............................................................................. 4-4
G
General (Inspection Techniques) .................................................................................................. 5-6a
General Penetrant Inspections ...................................................................................................... 3-1
General Procedures for Penetrant Inspection ................................................................................ 3-6
General Shop Rules...................................................................................................................... 2-2
Maintenance of Shop Equipment ............................................................................................ 2-2e
Responsibility ......................................................................................................................... 2-2a
Shop Housekeeping................................................................................................................ 2-2b
Shop Safety . .......................................................................................................................... 2-2c
Shop Tools and Materials ....................................................................................................... 2-2d
General, Electromagnetic Inspections .......................................................................................... 7-1
General, Magnetic Particle Inspections ......................................................................................... 4-1
General, Nondestructive Inspection............................................................................................... 2-1
General, Radiography ................................................................................................................... 5-1
General (Radiography Safety and Equipment) . ............................................................................ 5-11 a
General (Ultrasonic Inspection Equipment) ................................................................................... 6-8a
General, Ultrasonic Inspections .................................................................................................... 6-1
Index 3
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
H
Honeycomb, Fiberglass, and Composite Defects .......................................................................... T2-2
I
Importance of Skilled Operators ................................................................................................... 3-5
Indicators, Magnetic Particle . ....................................................................................................... 4-11
Inspection (Penetrant) .................................................................................................................. 3-12a
Inspection and Interpretation ........................................................................................................ 3-12
Inspection . ............................................................................................................................. 3-12a
Interpretation . ........................................................................................................................ 3-12b
Inspection Conditions ................................................................................................................... 3-11 a
Inspection of Bar Stock ................................................................................................................. 6-9f
Inspection of Metal Plates and Sheets .......................................................................................... 6-9e
Inspection of the Part ................................................................................................................... 3-14f
Inspection of Tubes and Pipes ..................................................................................................... 6-9g
Inspection Preparation .................................................................................................................. 4-6
Inspection Process, Selection of ................................................................................................... 3-9
Inspection Techniques .................................................................................................................. 5-6
Best Access to Object. ............................................................................................................ 5-6f
Degree of Sensitivity .............................................................................................................. 5-6d
Film Placement ...................................................................................................................... 5-6b
General.................................................................................................................................. 5-6a
Source-to-Film Distance . ....................................................................................................... 5-6c
Thickness Measurement . ....................................................................................................... 5-6e
Inspection, Penetrant, Types and Methods ................................................................................... T3-2
Inspection, Ultrasonic, Equipment ................................................................................................ 6-8
Inspection, Ultrasonic, Techniques ............................................................................................... 6-9
Inspections, Types of ................................................................................................................... 2-4
Interpretation and Inspection ........................................................................................................ 3-12
Interpretation (Penetrant Inspection) ............................................................................................ 3-12b
Interpretation (Radiographic) ........................................................................................................ 5-9, 5-9a
L
Lamb Waves................................................................................................................................ 6-6d
Leakage Field .............................................................................................................................. 4-3b
Lighting and Facilities ................................................................................................................... 3-11c
Limitations (Penetrant Inspection) ................................................................................................ 3-4
Limitations and Capabilities (Magnetic Particle Inspection) ........................................................... 4-5
Limits of Demagnetization............................................................................................................. 4-13d
Longitudinal Magnetization ........................................................................................................... 4-10
Amperage .............................................................................................................................. 4-10b
Applications . .......................................................................................................................... 4-1 0c
Equipment . ............................................................................................................................ 4-10d
Technique .............................................................................................................................. 4-10a
Longitudinal Waves ...................................................................................................................... 6-6a
Index 4
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
M
Magnetic Flux . ............................................................................................................................. 4-3e
Magnetic Particle Indicators ......................................................................................................... 4-11
Definitions .............................................................................................................................. 4-11a
Steps of Inspection . ............................................................................................................... 4-11b
Magnetic Particle Inspection, Fundamentals of ............................................................................ 4-4
Magnetic Particle Inspections, General ......................................................................................... 4-1
Magnetic Substances ................................................................................................................... 4-3d
Magnetism ................................................................................................................................... 4-3c
Magnetism, Theory of .................................................................................................................. 4-2
Magnetization, Circular . ............................................................................................................... 4-9
Magnetization, Longitudinal .......................................................................................................... 4-10
Maintenance of Shop Equipment................................................................................................... 2-2e
Manual Film Processing ............................................................................................................... F5-1
Materials, Consumable ................................................................................................................. 1-3
Methods of Application (Magnetic Particles) . ................................................................................ 4-7b
Methods of Application, Particles and............................................................................................ 4-7
Methods of Recording Indications (Magnetic Particle Inspection) ................................................. 4-12
Applying Transparent Tape . ................................................................................................... 4-12b
Dry Particle Indications ........................................................................................................... 4-12c
Fixing Indications with Lacquer .............................................................................................. 4-12a
Fluorescent Indications .......................................................................................................... 4-12e
Photographing Indications ...................................................................................................... 4-12f
Wet Particle Indications .......................................................................................................... 4-12d
Minimum Penetration Time For Penetrants ................................................................................... T3-1
Misinterpretation (Radiographic) ................................................................................................... 5-9b
Modes of Vibration . ...................................................................................................................... 6-6
Lamb Waves . ........................................................................................................................ 6-6d
Longitudinal Waves ............................................................................................................... 6-6a
Rayleigh Waves ..................................................................................................................... 6-6c
Transverse Waves ................................................................................................................. 6-6b
N
Nature of Sound Waves................................................................................................................ 6-5
NDI Shop Requirements ............................................................................................................... 2-3
Need for Both Types of Tests ....................................................................................................... 2-4c
Needle Deflections . ...................................................................................................................... 7-5d
Nondestructive Inspection, General............................................................................................... 2-1
Nondestructive Tests..................................................................................................................... 2-4b
O
Operation (Eddy Current Test Set) ................................................................................................ 7-5a
Operative Precautions................................................................................................................... 3-7b
Index 5
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
P
Particle Application, Current and .................................................................................................. 4-8
Particles ...................................................................................................................................... 4-7a
Particles and Methods of Application ............................................................................................ 4-7
Methods of Application............................................................................................................ 4-7b
Particles ................................................................................................................................ 4-7a
Penetrant Application ................................................................................................................... 3-10d
Penetrant Application (Type I, Method C)...................................................................................... 3-14c
Penetrant Inspection, Basic Principles of....................................................................................... 3-3
Penetrant Inspection, General Procedures for .............................................................................. 3-6
Penetrant Inspection, Type I, Method C......................................................................................... 3-14
Penetrant Inspection Types and Methods ...................................................................................... T3-2
Penetrant Inspections, General ..................................................................................................... 3-1
Penetrant Inspections, Precautions In ........................................................................................... 3-7
Penetrants, Minimum Penetration Time for ................................................................................... T3-1
Penetrants, Quality Control of ...................................................................................................... 3-8
Penetration Times......................................................................................................................... 3-10f
Permeability ................................................................................................................................ 4-3f
Personnel Requirements. .............................................................................................................. 2-5
Photographing Indications ............................................................................................................. 4-12f
Portable X-Ray Units .................................................................................................................... 5-7b
Pre-operative Precautions............................................................................................................. 3-7a
Precautions in Penetrant Inspections ............................................................................................ 3-7
Operative Precautions ........................................................................................................... 3-7b
Pre-operative Precautions ...................................................................................................... 3-7a
Safety Precautions ................................................................................................................. 3-7d
Temperature Limitations ........................................................................................................ 3-7c
Precleaning.................................................................................................................................. 3-10b
Precleaning Process (for Type C Penetrant).................................................................................. 3-14a
Preparation, Inspection ................................................................................................................. 4-6
Pretesting .................................................................................................................................... 3-10a
Pretesting, Precleaning, Drying, Application, and Removal ........................................................... 3-10
Developer Application ............................................................................................................ 3-10j
Developer Draining ................................................................................................................ 3-10k
Developer Dwell Time............................................................................................................. 3-101
Draining ................................................................................................................................. 3-10e
Drying.................................................................................................................................... 3-10c
Emulsifier Application . ........................................................................................................... 3-10g
Emulsifier Draining . ............................................................................................................... 3-10h
Emulsifier Dwell Time ............................................................................................................. 3-10i
Penetrant Application.............................................................................................................. 3-10d
Penetration Times................................................................................................................... 3-10f
Precleaning............................................................................................................................ 3-10b
Pretesting ............................................................................................................................... 3-10a
Removal Methods .................................................................................................................. 3-10m
Processing .................................................................................................................................. 5-8b
Index 6
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
P - Continued
Purpose (of Electromagnetic Inspections) ..................................................................................... 7-2
Purpose (of Manual)...................................................................................................................... 1-1
Purpose (of Penetrant Inspections)................................................................................................ 3-2
Purpose (of Radiography) ............................................................................................................. 5-2
Q
Quality Control of Penetrants ....................................................................................................... 3-8
Availability ............................................................................................................................. 3-8b
Compatibility .......................................................................................................................... 3-8a
R
Radiation Detection Standards ..................................................................................................... T5-1
Radiation Detectors ...................................................................................................................... 5-11c
Radiographic Interpretation . ......................................................................................................... 5-9
Interpretation .......................................................................................................................... 5-9a
Misinterpretation ..................................................................................................................... 5-9b
Radiographs, Filing ....................................................................................................................... 5-10
Radiography, General ................................................................................................................... 5-1
Radiography Safety Precautions and Equipment .......................................................................... 5-11
Electrical Precautions ............................................................................................................. 5-11d
Exposure Limits . .................................................................................................................... 5-11b
General.................................................................................................................................. 5-11a
Radiation Detectors ............................................................................................................... 5-11c
Rayleigh Waves........................................................................................................................... 6-6c
Reasons for Demagnetization ....................................................................................................... 4-13a
Recording Indications, Methods of (Magnetic Particle Inspection) ................................................ 4-12
Reflection..................................................................................................................................... 6-7a
Refraction and Mode Conversion .................................................................................................. 6-7b
Relative Response of Survey Meters ............................................................................................ T5-2
Removal of Developer ................................................................................................................. 3-14h
Removal of Excess Penetrant . ..................................................................................................... 3-14d
Removal Methods (Penetrants)..................................................................................................... 3-10m
Requirements, Personnel .............................................................................................................. 2-5
Residual Magnetism...................................................................................................................... 4-3g
Residual Method . ......................................................................................................................... 4-8a
Responsibility (for Shop Rules) ..................................................................................................... 2-2a
Retentivity ................................................................................................................................... 4-3h
S
Safety Precautions ....................................................................................................................... 3-7d
Safety Precautions and Equipment ............................................................................................... 5-10
Index 7
INDEX- CONT
Subject Paragraph,
Figure, Table
Number
S - Continued
Scope (of Manual) ........................................................................................................................ 1-2
Search Units . ............................................................................................................................... 6-8b
Selection of Inspection Process .................................................................................................... 3-9
Sensitivity Level ........................................................................................................................... 4-8e
Shop Housekeeping ...................................................................................................................... 2-2b
Shop Requirements, NDI .............................................................................................................. 2-3
Shop Rules, General . ................................................................................................................... 2-2
Shop Safety ................................................................................................................................. 2-2c
Shop Tools and Materials ............................................................................................................. 2-2d
Skilled Operators, Importance of .................................................................................................. 3-5
Sound Waves, Nature of .............................................................................................................. 6-5
Source-to-Film Distance ............................................................................................................... 5-6c
Special Techniques (Radiography)................................................................................................ 5-7
Fluoroscopy . .......................................................................................................................... 5-7a
Portable X-Ray Units............................................................................................................... 5-7b
Specific Procedures for Fluorescent Penetrant Inspection . ........................................................... 3-11
Black Light ............................................................................................................................. 3-11 d
Inspection Conditions ............................................................................................................. 3-11 a
Lighting and Facilities ............................................................................................................. 3-11c
Surface Preparation ............................................................................................................... 3-11 b
Steps of Inspection (Magnetic Particle Inspection)......................................................................... 4-11 b
Straight Beam Method . ................................................................................................................ 6-9a
Surface Preparation ...................................................................................................................... 3-11 b, 6-9d
Surface Wave Method .................................................................................................................. 6-9c
Survey Meters, Relative Response of ........................................................................................... T5-2
T
Technique (of Circular Magnetization)........................................................................................... 4-9a
Technique (of Longitudinal Magnetization) ................................................................................... 4-10a
Techniques for Demagnetization . ................................................................................................. 4-13c
Techniques, Inspection.................................................................................................................. 5-6
Techniques, Special (Radiography) .............................................................................................. 5-7
Temperature Limitations ............................................................................................................... 3-7c
Terminology, Basic (of Magnetism) .............................................................................................. 4-3
Test Set, Eddy Current, Model ED-520 ......................................................................................... 7-5
Testing Methods, Basic (Ultrasonics) ............................................................................................ 6-4
Testing Procedure (Eddy Current) ................................................................................................. 7-5b
Theory of Magnetism ................................................................................................................... 4-2
Thickness Measurement .............................................................................................................. 5-7e
Transducers ................................................................................................................................. 6-8c
Transmission Characteristics......................................................................................................... 6-7
Beam Divergence .................................................................................................................. 6-7c
Reflection ............................................................................................................................... 6-7a
Refraction and Mode Conversion............................................................................................ 6-7b
Index 8
INDEX - CONT
Subject Paragraph,
Figure, Table
Number
T - Continued
Transverse Waves ....................................................................................................................... 6-6b
Type I, Method C Penetrant Inspection ......................................................................................... 3-14
Application of Cleaner ............................................................................................................ 3-14b
Application of Developer ........................................................................................................ 3-14e
Evaluate Discontinuity . .......................................................................................................... 3-149
Inspection of the Part ............................................................................................................. 3-14f
Penetrant Application ............................................................................................................. 3-14c
Precleaning Process .............................................................................................................. 3-14a
Removal of Developer ........................................................................................................... 3-14h
Removal of Excess Penetration ............................................................................................. 3-14d
Types of Fluorescent Penetrant Processes ................................................................................... 3-13
Types of Inspections . ................................................................................................................... 2-4
Destructive Tests ......................................................................................................................... 2-4a
Need for Both Types of Tests........................................................................................................ 2-4c
Nondestructive Tests .................................................................................................................... 2-4b
U
Ultrasonic Equipment, Calibration of ............................................................................................ 6-10
Ultrasonic Inspection Equipment .................................................................................................. 6-8
General ................................................................................................................................. 6-8a
Search Units . ......................................................................................................................... 6-8b
Transducers ........................................................................................................................... 6-8c
Ultrasonic Inspection Techniques .................................................................................................. 6-9
Angle Beam Method . ............................................................................................................. 6-9b
Inspection of Bar Stock ........................................................................................................... 6-9f
Inspection of Metal Plates and Sheets ................................................................................... 6-9e
Inspection of Tubes and Pipes ............................................................................................... 6-9g
Straight Beam Method ........................................................................................................... 6-9a
Surface Preparation ............................................................................................................... 6-9d
Surface Wave Method ........................................................................................................... 6-9c
Ultrasonic Inspections, General .................................................................................................... 6-1
Use of Data ................................................................................................................................. 2-6
Uses of Eddy Current Inspection .................................................................................................. T7-1
V
Vibration, Modes of . ..................................................................................................................... 6-6
W
Wet Particle Indications ................................................................................................................ 4-12d
Index 9/(Index 10 blank)

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