NDT Application in Aircraft Industry / Human Faktor Effect

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NDT Application in Aircraft Industry / Human
Faktor Effect

• Short personal introduction
• Name Jirí 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 Unicov a.s.
• - Aircraft Industry
• LET Kunovice

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NDT Application in Aircraft Industry / Human
Faktor Effect
As a comitted member of CNDT regional group No. 6 North Moravia I got delegation from chairman of that group Mr. Solnar to hand over many regards to all attendants of this meeting.
October 6-10, 2014 Prague
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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

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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

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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

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NDT Application in Aircraft Industry / Human
Faktor Effect

• VISUAL INSPECTION METHODE
• Official acces panels
  
• Drain holes

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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.

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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 wiringetc.

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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.

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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).

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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 ? ?
  ?

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NDT Application in Aircraft Industry / Human
Faktor Effect

• PENETRANT TESTING METHODE
• Personal qualification request for information
  only

SAAB 340 BOEING 737 AIRBUS 320
Stated in NDT-M Stated in SOPM only PT procedure 20 pages Stated in NDT-M PT procedure 15 pages
NDT-M 51-08-00 SOPM 20-20-02 NDT-M 51-80-00 NDT-M 51-81-00
Related documents AMS 2644 ASTM E 1417 Related documents AMS 2644 ASTM E1417 Related documents AMS 2644 ASTM E 1417
PT in NTM and Immediately in introduction there is a request for qualification I.A.W EN 4179 NTM does not contain PT There is no request for qualification PT in NTM But there is no request for qualification
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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)

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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

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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 ? cL / f
  5,92 / 4 1,48 mm
  ? / 4peaks 1,48 / 4
  0,37 mm
• 
  For us Al mat. and 12
  MHz probe
• 
  (6,32 /
  12 / 4 0,131mm)
• 
  
• 
  

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NDT Application in Aircraft Industry / Human
Faktor Effect

• ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
• (nominal thickness proficiency)

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NDT Application in Aircraft Industry / Human
Faktor Effect

• ULTRASONIC TESTING / FUSELAGE THICKNESS CHECK
• (nominal thickness proficiency)

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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

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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)
  

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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

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NDT Application in Aircraft Industry / Human
Faktor Effect

• MAGNETIC PARTRICLE TESTING METHODE
• Human faktor effect unexpected residual
  magnetism
• (unallowable on engine parts and others)

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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.

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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

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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 .

Alloy Temper IACS MS/m
2024 0 45,5 - 49,0 26,4-28,4
7075 0 44,0 - 47,5 25,5-27,5
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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

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NDT Application in Aircraft Industry / Human
Faktor Effect

• Easy? Conclusion
• VT methode
• Always make sure you know, what are you
  looking for !
• PT method
• Remember aircraft producer different stand to
  personal qualification and think about rigt
  penetrant type and sensitivity application !
• UT-T method
• Recorded thickness compare with drawing and/or
  documentation before final evaluation
• MT method
• Even use alternating current always check
  residual magnetism and use demagnetizing coil in
  any case !
• ET method
• Consider all indirect influence to recorded IACS
  value before you make final decision !

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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.