NonDestructive Inspection NDI 25 Jan 07

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Non-Destructive Inspection (NDI) 25 Jan 07
OKLAHOMA CITY AIR LOGISTICS CENTER
TEAM TINKER
Mr. Dave Campbell 76 MXSS/MXDEBB
dave.campbell_at_tinker.af.mil
I n t e g r i t y - S e r v i c e - E x c e l
l e n c e
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NDI Tech Need 1
NDI Paperwork Reduction Act of 2007
Problem
NDI inspectors and technicians do as much paper
work as NDI.
Problem
Collection of MX data recognized by AFMC/EN as
critical to the ability to maintain our aging
weapon systems.
Goal
Reduce the paperwork burden of the inspector AND
improve quality and consistency of defect
reporting.
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The Vision
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NDI Tech Need 1
NDI Paperwork Reduction Act of 2007
Problem
NDI inspectors and technicians do as much paper
work as NDI.
Problem
Collection of MX data recognized by AFMC/EN as
critical to the ability to maintain our aging
weapon systems.
Goal
Reduce the paperwork burden of the inspector AND
improve quality and consistency of defect
reporting.
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NDI Tech Need 2
Fresh Look
Objective
Look at our NDI processes to determine if there
are new technologies that can be implemented to
improve performance.
Increase probability of detection (PoD), reduce
inspection times, reduce inspector burden, reduce
waste streams, etc
Goal
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Scope
3 Production Groups
300,000 manhours per year
196 certified inspectors
22 NDI sub-techniques
Manual surface eddy current Manual bolt hole eddy
current Manual low frequency eddy
current Automated surface eddy current Semi-automa
ted high/low frequency eddy current Conductivity
Testing
18 facilities
7 buildings
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For Example The Aircraft shop performs 8000
inspections per year in 15 buildings (some with
multiple locations) plus 3 ramp areas.
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NDI Tech Need 2
Parameters
1) Probability of Detection (PoD)
2) Ergonomics
3) Inspection time
4) Hazardous waste
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NDI Tech Need 2
1) Probability of Detection (PoD)
Estimates only. AF currently conducting PoD
studies on surface eddy current.
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NDI Tech Need 2
2) Ergonomics
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NDI Tech Need 2
3) Inspection time
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NDI Tech Need 2
4) Hazardous waste
a) FPI and MPI chemical waste streams
b) Ultrasonic couplant
c) Ultraviolet radiation
d) X-ray film development chemicals
e) Silver in x-ray chemical waste stream
f) Lead in film packs
g) X-radiation
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Process Improvement Example
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Fluorescent Penetrant Inspection
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Total elapsed time from 1.0 to 8.0 hours per
inspection.
PoD, Inspection Times, and Waste Stream
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Jet Engine Blade Inspection
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Sonic Infrared Whole Field Inspection for Blade
Inspection
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Experimental Setup
Ultrasonic welder
Vibrometer
Data acquisition system
IR camera
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Experimental Setup
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PoD ?
More complex ?
Drive up training costs ?
Drive up equipment costs ?
Introduce noise hazard ?
Damage to the part ?
Total elapsed time is seconds and minutes, not
hours.
Reduced inspection times, reduced waste
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NDI Tech Need 2
Fresh Look
Objective
Look at our NDI processes to determine if there
are new technologies that can be implemented to
improve performance.
Increase probability of detection (PoD), reduce
inspection times, reduce inspector burden, reduce
waste streams, etc
Goal
Problem
Any new or novel NDI technology will require
exhaustive testing to ensure capabilities.
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Tinker NDI Tech Needs
Goal
Reduce the inspector burden AND improve quality
and consistency our inspections.
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David Campbell Campbell David R Civ 76
MXSS/MXDEBB David.campbell_at_tinker.af.mil
Building 3220 Room 128