NON-DESTRUCTIVE

TEST MANUAL

INTRODUCTION

CFMI-TP-NT.11 NOVEMBER 30, 1980

REVISED MAY 31, 1992
 INTRODUCTION
LIST OF EFFECTIVE PAGES

SECTION PAGE DATE

TAB
DIVIDER

TITLE
PAGE

LIST OF
EFFECTIVE
R PAGES 1 May 31/92
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R INTRO 1 May 31/92

2 Feb 28/91
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8 Feb 28/91
9 May 31/81
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R: indicates pages added, changed, or deleted this revision.

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 INTRODUCTION

1. Organization of the Non-Destructive Test Manual.

A. Manual Breakdown.

(1) The Non-Destructive Test Manual (NDTM) is divided into Parts

(methods of testing) defined by Air Transport Association (ATA)
Specification 100. CFMI may assign some Part numbers differently
than those found in the specification. CFMI may also have
additional requirements to those found in the specification.

(2) The Parts that follow are contained in this manual.

Part 1 - General
R Part 2 - Not applicable
Part 3 - Gamma Ray
R Part 4 - Not applicable
Part 5 - Not applicable
Part 6 - Not applicable
Part 7 - Borescope Inspection
Part 8 - Fluorescent Penetrant Inspection
Part 9 - Spectrometric Oil Analysis Program (SOAP)
Part 10 - Chip Analysis
Part 11 - Not applicable

(3) Additional Parts may be introduced into the NDTM, as the engine
program develops, to provide economical and reliable inspections.

(4) Each Part of this manual will have the following general scope of
coverage:

General Technical Principles.

Safety.

Equipment and/or Facilities.

Preparation and Operation.

Inspection of the Engine, Component, or Part.

Record of Inspection.

Specific Procedure.

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 B. Numbering Systems. See figure 1.

(1) This manual employs the 3-element (6 digit) ATA 100 numbering
systems. The first element denotes the chapter/system, the second
the section/sub-system and the third the subject or item.

(2) In this manual the sixth digit will always be zero.

(3) Parts.

(a) Each Part begins with a tab divider, a title page, a list of
effective pages and a table of contents.

(b) The list of the effective pages shows the date of the most
recent revision.

2. Engine Directional References. See figure 2.

Clockwise, counterclockwise, clock position and other directional

references apply to the engine in a horizontal position, viewed from the
rear, and with the accessories section at the bottom. When components or
struts are numbered circumferential direction the No. 1 position is at
12 o'clock, or immediately clockwise from 12 o'clock. The remaining
positions increase arithmetically in a clockwise direction.

3. Flange Identification. See figure 3.

The external flanges of the engine have been assigned letter designations.
The letter designation will be used for flange identification wherever it
is necessary to be explicit about flange location, such as positioning of
brackets, clamps, bolts, etc.

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 ATA Numbering of Engine Sections
Figure 1

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 Engine Directional References
Figure 2

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 Flange Identification
Figure 3

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 B. Horizontal flanges are identified by:

(1) Front stator case horizontal left flange.

(2) Front stator case horizontal right flange.

4. Use.

This manual is to be used in conjunction with applicable Maintenance

Manual and other applicable inspection equipment manufacturer's, Operating
and Service Instructions. All findings of these inspections shall be
interpreted according to limits of serviceability shown in the maintenance
manual.

A. Definitions.

The following terms are used in the NDTM and are defined as follows:

NOTE: Notes call attention to methods which make the job easier, or
provide supplementary or explanatory information.

CAUTION: CAUTIONS CALL ATTENTION TO METHODS AND PROCEDURES WHICH, IF

NOT PRECISELY FOLLOWED, POSE A PARTICULAR RISK OF EQUIPMENT
DAMAGE.

WARNING: WARNINGS CALL ATTENTION TO METHODS, PROCEDURES OR LIMITS

WHICH, IF NOT PRECISELY FOLLOWED, POSE A PARTICULAR RISK OF
INJURY OR DEATH TO PERSONS.

B. Assumptions.

The following assumptions were made in connection with the use of this
manual.

(1) That the personnel doing these inspections are properly trained,
qualified and/or licensed, where such licensing is required by
law.

(2) That the personnel doing these inspections know and will ensure
compliance with applicable Federal, State, and Local Rules and
Regulations.

5. Supporting publications.

The following is a list of publications written in support of CFM56

engine.

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 A. Maintenance Manual.

The Maintenance Manual presents detailed information required to

support the engine at a flight-line level. Inspection and checks,
flight-line repair procedures or limits, and operation and
troubleshooting comprise the major portion of the publication.
Descriptions of the engine sections, systems, and components are
included to familiarize operation personnel with the various
components.

B. Operating Instructions.

The operating instructions give operating limits and special operating

procedures useful for pilots and maintenance personnel who will operate
the engines. These instructions are not to be used for testing the
engines after line maintenance.

C. Illustrated Parts Catalog.

(1) The Illustrated Parts Catalog lists and illustrates all parts and
assemblies of the engine. It is intended only for requisitioning,
storing, issuing, and identifying parts and for illustrating
relationship for disassembly, where applicable. It is no to be
used as the authority for procedures of assembly or disassembly.

(2) The catalog is also a historical record of parts used, superseded,

and /or discontinued.

D. Illustrated Tool and Equipment Manual.

The Illustrated Tool and Equipment Manual provides information on the

special tools and equipment required for the CFM56 engine. The tools
and equipment are illustrated with a brief description of the tool and
its use.

E. Engine Shop Manual.

(1) The Engine Shop Manual presents detailed information required to

support the engine at shop level.

(2) Inspection, repair procedures, testing and troubleshooting

comprise the major portion of this publication. Description of
the engine sections, and components, are included to familiarize
personnel with the terminology and physical appearance of the
various components.

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 F. Component Maintenance Manuals.

(1) The Component Manuals contain detailed maintenance or overhaul

instructions for the accessories furnished on the engine.

(2) The manual covers disassembly, cleaning, inspection, approved

repairs and repair methods, assembly and testing of the
accessories. The manuals also include an Illustrated Parts
Catalog for each of these accessories.

G. Facility Planning Manual.

The Facility Planning Manual provides the information to aid airline

planners in developing the facilities and equipment requirements for
the CFM56 engine. Equipment, space, manpower skills and processes
requirements are given on a broad base so individual airlines can fit
it to their operation.

H. Standard Practices Manual.

This Manual covers frequently used processes and procedures that are
used in the maintenance and repair of engine parts.

I. Consumable Products Manual.

The Consumable Products Manual presents technical data on all products

used in maintenance of the CFM56 engine.

6. Definition of Terms and Abbreviations.

A. Defects.

The following terms are used to describe/define defects.

Terms Definition Associated Terms

R Blister A raised portion of a Bubble

surface caused by Flaking
separation of the outer Oxide Formation
layers of the parent Peeling
material or of a Scale
coating applied to it. Slag inclusion
(weld)

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 Terms Definition Associated Terms

Brittle A change in the Cold worked hard

elasticity or resilience (like an old
of the parent material O-ring)
usually caused by aging,
extreme cold, chemical
action, or cold-working.

Buckle A large-scale deformation Ballooning

of the original contour Bend
of a part, usually caused Bulge
by pressure or impact Crease
from a foreign object. Curl
Structural stresses, Dent (not to be
excessive localized confused with
heating, high-pressure small-area defect
differentials, or any in heavy material)
combinations of these. Depression
Distortion
Elongation
Fold
Indentation
Kink
Protrusion
(hollow)
Rupture (result of
excessive
buckling)
Uneven
Warpage
Wrinkle

Burn A rapid, destructive, Burn out (missing

oxidizing action, usually piece)
caused by higher Erosion
temperatures than the Corrosion
parent material can Guttered
withstand. Change in Heat-check
color appearance often Heat deterioration
indicates this condition. Hole (burn)
Hot spot
Overheated
Oxidation

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 Terms Definition Associated Terms

Burnishing Smoothing of a metal Rub

surface by mechanical Wear
action, but without a
loss of material.
Generally found on plain
bearing surface. Surface
discoloration is
sometimes visible around
the outer edges. Normal
burnishing from
operational service is
not detrimental if the
coverage approximates the
carrying load and there
is no evidence of burns.

Burr A rough edge or a sharp

protusion on the edge or
surface of the parent
material.

Chafing See "Gall" or "Scratch".

Chip A breaking away of the Break

edge of the parent Nick (similar to Chip, but
material, usually caused no parent material is
by heavy impact from a removed). Notched
foreign object. Spalling (usually a
broken-away flat surface).

Corrosion A mass of small pits Pit

which cumulatively create
a large, shallow cavity
(usually rough in the
surface of the parent
material).

Crack A parting or Break

discontinuity in the Cold shut
parent material (castings)
Crater (castings)
Fatigue damage
Fissure
Fracture
Lap (forgings)

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 Terms Definition Associated Terms

Crack (Cont'd) Rupture

Seam
Separation
Slit
Tear

Crazing A mesh of minute hairline

cracks found in glazed or
baked-on coated surfaces,
generally caused by
temperature change or by
deformation of parent
metal. Cracks do not
penetrate into parent
metal.

Creep Gradual continous

distortion or plastic
flow under constant
stress.

Deformation Any alteration or change Bend

of shape, dimension or Creep
configuration resulting Distortion
from stress or damage.

Dent A completely smooth Peen

surface depression caused
by pressure or impact
from a smooth, rounded
foreign object. The
parent material is
displaced, but none is
separated.

Deviation Any condition that causes Damage

a part to differ from the Defect
manufacturer's blueprint. Flaw
Imperfection
Irregularity

Discontinuity An interruption in the Crack

normal physical structure Seam
or configuration of a Cold shut
part. Lap

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 Terms Definition Associated Terms

Distortion Any twisting, bending or Bend

permanent strain that Deformation
results in misalignment
or change of shape.

Erosion Gradual wearing away of a

surface caused by a fluid
(gas or liquid) flowing
over the surface. Wear
is generally caused by
fine particles of foreign
material entrained in hot
engine gases flowing at a
high velocity.

Fatigue The progressive fracture Crystallization

of a material under Fretting
cyclic stress loading. Flaking

Flaking See "Spalling".

Fretting Wearing away by low- Wear

amplitude rubbing against Galling
another metal (generally
associated with press fit
or close fitting parts).

Galling A defect caused by the Pickup

movement of 2 surfaces in
contact with each other.
In most cases, an
accumulation of foreign
material is deposited on
the parent material.

Gouge A wide, rough scratch or

group of scratches,
usually with one or more
sharply incised corners,
and frequently
accompanied by
deformation or removal or
parent material.

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 Terms Definition Associated Terms

Groove A long, narrow, If depression is shallow

continuous depression and smooth see "Wear"; if
caused by pressure of a depression is sharp, see
moving surface in contact "Scratch".
with the parent material.

High spots Local distortions Blister

Buckle
Bubble
Out-of-round

High metal Displaced metal adjacent Burr

to a defect such as a
scratch, nick or gouge,
which is raised above the
surrounding.

Imbalance The state of being out-

of-balance. Unequal
distribution of weight
about the axis of
rotation, which usually
results in vibration.

Inclusion Foreign material embedded

in metal during
solidification, or formed
by subsequent reaction of
the solid metal.

Indication The visible evidence that

a material defect exists,
even though the defect
itself may not be visible
to the naked eye.

Looseness Abnormal movement of a Backet out

part, or insufficient Excessive play
securing of a part. Excessive
backlash
Insufficient
torque
Shaky
Sloppy
Unbottomed
Unpinned
Unwired

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 Terms Definition Associated Terms

Misalignment A mismatching or Eccentric

malformation of any part Out-of-round
which either prevents Out-of-square
perfect assembly or Mismatched
results in faulty Unmatched
operation and/or ultimate
failure.

Nick A surface impression with Chip

sharp corners or bottom, Dent
usually caused by Notch
pressure or impact from a
sharp-edged object. The
parent material is
displaced, but usually
none is separated.

No Apparent Term used to describe

Depth surface defects that can
be seen but not felt with
fingernail or
scriberpoint.

Noise An abnormal sound Bumps (sound)

involving moving parts, Chatters
usually an increase in Clicks
volume or a change of Grates (usually
pitch. gears)
Grinds
Hums
Rattles
Rubs
Scrapes (sound)
Screeches
Thumps
Whistles

Obstruction Prevention of free flow Clogged

of a fluid (air, oil, Contaminated
fuel, water) because of Plugged
foreign material in the Restricted
flowpath or malformation
of the part.

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 Terms Definition Associated Terms

Oil-canning Shapping or popping Buckling

(Snapping displacement of sheet
action) metal when restrained at
its edges like a
diaphragm, wall, or
bottom of an oil can.

Parent Metal All material in a single

part except the weld,
braze filler, or heat-
affected zone (within
1/8 inch (3.175 mm) of
the fusion line).

Pickup Transfer of one material Burr

into or onto the surface Gall
of another in contact Imbedment
with it, usually as a Inclusion
result of friction- Pile-up
heating. Protrusion
Metallization

Pinched Distortion of one or more Bound

surfaces of the parent Compressed
material, caused by Flattened
pressure Seized
Smashed (without
separation into
pieces)
Squashed
Squeezed

Pit A minute depression or Corrosion

cavity having no sharp, Crater
high-stress corners in Electrolytic
the surface of the cavity
material. Pits are Inclusion
usually caused by Perforation
chemical reaction Pinholes
(rusting, chemical Pock-marked
corrosion).

Porosity Areas containing numerous Pit

pits or pinholes Pinholes

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 Terms Definition Associated Terms

Rub A surface depression or If impression is

displacement caused by shallow and
two surfaces moving while smooth see
in contact with each "Wear". If
other. impression is
sharp, see
"Scratch".

Scale A layer of metallic Burn

oxides formed by chemical
action of oxigen on the
exposed surface of the
metal, usually while hot.

Scratch A long, narrow, sharp- Abrasion

cornered impression Chafe
caused by the movement of Furrow
a sharp object across the Groove
surface of the parent Score
material.

Seizure A welding or binding of Bound up

faces which prevent Frozen
further movement. Tight
Wedged
Welded (without
external
heating).

Spalling Cracking off or flaking Flaking

off of small particles of Fretting
metal from the surface, Galling
usually in thin layers or
localized spots.

R Tear A physical separation, Burr

R pulling apart, or Chip
R wrenching of metal which Crack
R can be caused by impact Nick
R damage.

Unbalance The act of putting a

balanced component out of
balance. Usually
"imbalance" is meant.

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 Terms Definition Associated Terms

Varnish film A hard surface-film of Banded

partially carbonized Discolored
hydrocarbon, such as oil, Oxidized
which is built up when the Stained
part is heated to or above
the breakdown-point of the
fluid.

Wear Relatively slow removal of Abrasion

parent material in the Attrition
process of operation (not Brinnelled
always visible to the Chafed
naked eye). Chattering
Erosion
Fraying
Fretting
Friction
Galling
Glazing
Groove
Interference
Oxidation
Roughness
Rubbed
Scarfed
Scuffed
Uneven
Weak

B. Abreviations.

The following abbreviations have been used for terms that appear within
the manual.

LRU Line Replaceable Unit

TGB Transfer Gearbox
AGB Accessory Gearbox
LPT Low Pressure Turbine
HPT High Pressure Turbine
MEC Main Engine Control
PMC Power Management Control
VSV Variable Stator Vane
VBV Variable Bleed Valve
N1 Low Pressure Rotor Speed
N2 Core Rotor Speed

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