Structural Inspection and Repair Manual (Rev D0) 20-00-00-2 (Rev D0) ‘STANDARD PRACTICES AIRFRAME 1, Fluorescent Liquid Penetrant inspection NOTE: The inspection procedures described in this chapter are provided as general information on the subject and are not intended to substitute for competent training. Should any unusual conditions be found that cannot be resolved locally, contact Textron Aviation Technical Support for evaluation and possible solutions. A. Personnel Personnel performing the inspections called outin this manual must meet the requirements as stated in the Introduction Section ofthis manual WARNING: increased usage of "high-solids” paint systems has necessitated a revised approach requirement for stripping of painted surfaces prior to fluorescent liquid penetrant inspection. Remove paint and primer when specified from area to be fluorescent penetrant inspected. Caution should be exercised as some paint strippers may contribute to corrosion. All structure adjacent to the area ‘subjected to chemical stripping solutions should be protected to ensure stripper does not migrate into joints and does not contact surfaces other than that designated to be stripped. Ensure adequate cleaning of the stripping solution as this could render the penetrant system inoperable, NOTE: All components of the penetrant inspection system must be from the same manufacturer and designed to be used together. For instance, itis not permissible to use a penetrant from one manufacturer and a cleaneriremover from another manufacturer to inspect the same workpiece. Fluorescent quid penetrant inspection is a non-destructive method for finding cracks or other discontinuities that are open to the surface of solid and essentially nonporous materials, This method utilizes penetrants which fluoresce brilliantly under ttraviolet (black) ight. Indications of damage can be found regardless of the size, configuration, internal structure or ‘chernical composition ofthe workpiece being inspected and regardless of the orientation of the damage. The fluorescent liquid penetrant inspection method has been developed into three basic processing systems characterized by the penetrant being water-washable, post emulsifiable or solvent-removable, For the purpose of conducting the inspections ‘covered in his manual, a solvent removable fluorescent quid penetrant system such as the Zyglo (registered trade name of the Magnaflux Corp.) three component kit (2, Chart 210, 91-00-00) is recommended. To perform an inspection using the fluorescent liquid penetrant method, these essential Steps must be followed NOTE: Aerosol nonreusable penetrant system is required. a. SURFACE PREPARATION - All surfaces of a workpiece must be thoroughly cleaned with solvent (2,3, Chart 208, 91-00-00) and completely dried before they are subjected to the fluorescent liquid penetrant inspection b. PENETRATION - After the workpiece has been cleaned, the fluorescent quid penetrant is applied by aerosol spray ora brush to forma film of penetrant over the surface being inspected, The fim must remain on the workpiece long enough to allow maximum penetration of the penetrant into any surface openings that may exist. For applications described in this manual, a minimum of 30 minutes dwelltime ata minimum temperature of 60°F is required, ©. REMOVAL OF EXCESS PENETRANT - Optimum removal ofthe excess penetrant is accomplished by wiping off ‘aS much of the penetrant as possible with a paper towel ora lint-free cloth; then wipe off the remaining penetrant with a clean cloth slightly dampened with the penetrant system cleaner, and finally, wipe with a dry paper towel or clean cloth. Do not spray system cleaner directly on the part to clean off excess penetrant. This could cause the removal of penetrant from any cracks which may be present. d. DEVELOPMENT - The developing agent is applied by aerosol spray to form a film over the surface to be inspected. The developer acts as a blotter to assist the natural seepage of the penetrant out of any surface ‘openings and to spread it atthe edges to greatly magnify the apparent width ofthe opening. The developer also provides a uniform background to assist damage interpretation. Caution should be used in the application of the developer to provide the optimum coating thickness. Ifthe coating thickness is too thinly applied, the penetrant will not be spread and a crack or other discontinuity will not be easily detected. f the developer coating thickness is too thickly applied, the penetrant might not bleed through the coating fe. INSPECTION- After being sufficiently developed, the surface is visually examined for indications of penetrant bleedout from surface openings. This examination must be performed under suitably darkened conditions for the Penetrant to fluoresce during exposure to ultraviolet light. A model ZB-23A (P/N Maghatlux Corporation) or ‘equivalent utraviolet (black) ight that meets the following minimum requirements must be used for this inspection: (1) 3600- to 4200-angstrom wave length, (2) 1000 micro watts per centimeter squared at 15 inches from the Copyright © Textron Aviation ne Page 1 of 32 stn pte eas or Me eras ely Fer re menos, cy cet a Print Date: Fri Jan 11 06:28:55 CST 2018Structural Inspection and Repair Manual (Rev D0) 20-00-00-2 (Rev D0) surface to be inspected. {POST INSPECTION CLEANING. After completion of the fluorescent liquid penetrant inspection, the inspection ‘areas must be thoroughly cleaned to remove the developer coating and any remaining traces of the penetrant 2. Magnetic Particle Inspection A Personnel Personnel performing the inspections called outin this manual must meet the requirements as stated in the Introduction Section ofthis manual Magnetic particle inspection is a method for locating surface and subsurface discontinuities in ferromagnetic materials (Le. materials capable of being magnetized); consequently, non ferromagnetic materials (such as aluminum alloys, magnesium alloys, copper alloys, lead, titanium alloys, nickel-based alloys such as Inconel and many stainless steel alloys) ‘cannot be inspected by this method. Magnetic particle inspection is based upon the principle that any discontinuities laying in a direction generally transverse to the direction of the magnetic feld ofthe part being magnetized forthe test will ‘cause a leakage field to be formed at and above the surface of the part. The presence of the leakage field denoting the discontinuity is detected by the use of finely divided ferromagnetic particles over the surface of the part. Some of the particles are magnetically gathered and held by the leakage field to form an outline indicating the location, size, shape and ‘extent ofthe discontinuity. In general, magnetic particle inspection utiizes a variety of types of equipment for magnetization as well as several methods for application of ferromagnetic particles to the test part. Additionally, the ferromagnetic particles are available in a variety of colors (including fluorescent) and shapes. Magnetic particle inspections required by this manual can best be accomplished utlizing the wet continuous method on the standard wet-horizontaltype equipment with either visible or fluorescent magnetic particles suspended in a petroloum-based vehicle (normally kerosene). Since magnetic particle indications are best obtained when the discontinuity lies ina direction transverse to the magnetic field, the following procedures are recommended for optimum detection of discontinuities in both bolts and nuts. WARNING: Improper operation of magnetic particle inspection equipment, because of faulty equipment or by untrained persons, can jeopardize the airworthiness of parts being inspected. Minute electrical arc burns caused during the inspection by improper operation of the test equipment can result in ‘eventual failure of the part. Bolts: spection of a boltis accomplished by longitudinal magnetization ina multitun low-ill factor col (i.e. the inner diameter of the coll greatly exceeds the bolt diameter). For proper magnetization the bottis positioned close to the inside ‘coil wall with the bot length perpendicular to the winding direction. The magnetic particle suspension is flowed on the bolt ‘and the appropriate currents applied to achieve adequate field strength. Using the described procedure, laboratory testing has indicated that the ampere tum values listed in Chart 201 provide for optimum detection of discontinuities perpendicular to the bol axis. ‘Nuts: Inspection of a nutis accomplished by circular magnetization on a central conductor (usually a copper rod) the approximate size of the inside diameter of the nut. For proper magnetization the central conductor bar is inserted through the nut and the bar is positioned between the heads of the wet horizontal equipment. The magnetic particle suspersion is flowed an the rut and the appropriate curent is applied through the central conductor to achieve adequate field strength. Using the described procedure, laboratory testing has indicated that the amperage values listed in Chart 202 provide for ‘optimum detection of discontinuities parallel to the nut axs. ‘After magnetic particle inspection, the parts must be carefuly demagnetized and cleaned of the ferromagnetic particles. Carefully check parts for evidence of any possible electric arc bum that may have occurred during the inspection. Table 201. Magnetic Particle Inspection (Stee! Bolts) Bolt Diameter Total Bolt Length Including Head ‘Ampere Tums To Nearest 1/4 Inch 5/8 inch 242 Inch 7300 5/8 Wnch 2.314 Inch 7100 5/8 inch ‘Sinch 6600 3/4 Wneh ‘Snch 7900 3/4 wnch 3.414 Inch 7400 3/4 Wnch 342 Inch 6700 3/4 Wnch 3.304 Inch 6300 Copyright © Textron Aviation ne Page 2 of 32 stn pte eas or Me eras ely Fer re menos, cy cet a Print Date: Fri Jan 11 06:28:55 CST 2018Structural Inspection and Repair Manual (Rev D0) 20-00-00-2 (Rev D0) 718 lich 3172 Inch 7900 78 Weeh 3.3/4 Inch 7400 7/8 Weeh 4 inch 6900 7ie Wech 5 inch 5500 Then ‘Sch 6300 NOTE: Amperage requirement is the ampere tums value divided by the number of turns on the coll. For ‘example: A 1-inch-diameter x 5-inch-Jong bolt tested on a 5-tum coil would require 6300+ 5, or 1260 amps. Table 202. Magnetic Particle Inspection (Stee! Nuts) Nut Size Central Conductor Size ‘Amperage 5/8 inch 12h ‘500 3/4 wnch 5/8 ch 600 7/8 wen 3/4 Wnch 700 Then 7/8 Weh ‘800 3. Eddy Current inspection WARNING: This document does not intend to address all of the safety concems, if any, associated with i's use. It shall be the responsibility of the users of this document to determine the applicability of any regulatory limitation before its use, and to establish appropriate health and safety practices. A. Special Tools and Equipment Each tool listed in Chart 203 is provided as an example of the equipment designed to perform a specific function, Generic ‘or locally manufactured tools that are the equivalent with respect to accuracy, function, and craftsmanship may be used in eu of those listed, Table 203. Special Tools and Equipment Tool Name Part Number ‘Supplier Use 1. Edy Curent |NDT-9EN{(Staveley 190) or [Staveley instumenis421 Instrument (Phase [equivalent North QuayKennewick, Analysis) WA99336-7735 2. Eddy Current 90° |MP902-50 or equivalent [NDT Engineering Corp. ‘Surface Probe 19620 Russell RoadKert, (60-500KH2) (1/8 Wa 98032-1115 inch diameter, shielded probe) 3. EddyCurent —_[MP-S0 or equivalent NDT Engineering Corp. Straight Surace 19620 Russell RoadKent, Probe (50 wa 98032-1115 ‘S00KH2) (1/8 inch diameter, shielded probe) 4. Eddy Current Bot [Part number varies with the | NDT Engineering Corp. Hole Probe: diameter of hole to be 19620 Russell RoadKert, (1ooKHe- 2M) |inspected. Use appropriate | WA 98032-1115 (Shielded Probe [supplier part number or with applicable equivalent to testitem. diameter for the hole size to be inspected) Copyright © Textron Aviation ne Page 3 of 32 stn pte eas or Me eras ely Fer re menos, cy cet a Print Date: Fri Jan 11 06:28:55 CST 2018