Non-Destructive Testing Manual 06 15 2008

Non-Destructive
Testing
Manual
Volume 8
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NON-DESTRUCTIVE TESTING MANUAL
Record of Revisions Page

Volume 8

Record the date of insertion and your initials on this page.
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REV. 00, 01 OCT 2007 ROR-1


Volume 8
REV. 00, 01 OCT 2007 ROR-2

Non-Destructive Testing Manual
Temporary Revision Record

Volume 8

Temporary Revisions are issued on an as needed basis to convey timely information. Temporary
Revision information may supersede current information found in this manual or introduce new pro-
cedures due to changes in the regulatory or operating environment. Temporary Revisions will have
either a verbal or written FAA acceptance or approval prior to distribution. Temporary Revisions are
inserted in the area so designated on the first page of the Temporary Revision. Their insertion or
removal is recorded below. CD-ROM versions of this manual will have the Temporary Revision
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sions will be removed once the material covered is incorporated into a manual revision (usually the
next revision), or is no longer valid. Temporary Revisions will be numbered consecutively unless
otherwise noted.
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REV. 01, 01 MAR 2008 TRR-1


Volume 8
Temporary Revision Summary Record

Chapter/
Temporary Date Date
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Revision No. Issued Removed
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REV. 01, 01 MAR 2008 TRR-2

Highlights - Revision 2
Volume 8
1) Chapter 1, added all new material.
2) Chapter 2, title changed to Ultrasonic.
3) Chapter 2, Section 1, title changed to Contact Ultrasonic.
4) Chapter 3, Section 3, Ultrasonic (UT) added.
5) Chapter 3, Section 5, Ultrasonic added.
6) Chapter 3, Section 9, Item D. added (Ultrasonic Testing Training Course).
REV. 02, 15 JUN 2008 HGH-1

Volume 8
REV. 00, 01 OCT 2007 HGH-2

List of Effective Pages

Volume 8
Page Revision/Dated Page Revision/Dated
ROR-1 . . . . . . . . . . . . REV. 00, 01 OCT 2007 3-11. . . . . . . . . . . . . . . REV. 01, 01 MAR 2008
ROR-2 . . . . . . . . . . . . REV. 00, 01 OCT 2007 3-12. . . . . . . . . . . . . . . REV. 01, 01 MAR 2008
TRR-1 . . . . . . . . . . . . REV. 01, 01 MAR 2008 3-13. . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
TRR-2 . . . . . . . . . . . . REV. 01, 01 MAR 2008 3-14. . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
HGH-1 . . . . . . . . . . . . . REV. 02, 15 JUN 2008 3-15. . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
HGH-2 . . . . . . . . . . . . REV. 00, 01 OCT 2007 3-16. . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
LEP-1 . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
LEP-2 . . . . . . . . . . . . . . REV. 02, 15 JUN 2008
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REV. 02, 15 JUN 2008 LEP-1


Volume 8
REV. 02, 15 JUN 2008 LEP-2

Table of Contents
Volume 8
Table of Contents
Record of Revisions Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROR-1
Temporary Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . TRR-1
Highlights - Revision 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HGH-1
List of Effective Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEP-1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOC-1
Chapter 1 Eddy Current Examination

Section 1 General High Frequency Eddy Current (HFEC) Procedure . . . 1-1
A. Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
B. Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
C. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
D. Performance Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
E. Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
F. Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
G. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
H. Equipment Calibration for Inspection of Aluminum Alloy Material . 1-5
I. Equipment Calibration for Inspection of Titanium Alloy Materials . 1-7
J. Equipment Calibration for Inspection of 4130, 4340, 300M Alloy Steel
and Similar High Permeability Steel Parts . . . . . . . . . . . . . . . . . . . 1-9
K. Inspection Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
L. Evaluation of Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
M. Acceptance or Rejection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Section 2 Eddy Current Process Control . . . . . . . . . . . . . . . . . . . . . . . . 1-17
A. Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
B. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
C. Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
D. Probe Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
E. Standard Slot Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Chapter 2 Ultrasonic
Section 1 Contact Ultrasonic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
A. Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
B. Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section 2 Equipment and Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
A. Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
B. Performance/Equipment Verification . . . . . . . . . . . . . . . . . . . . . . . 2-2
REV. 02, 15 JUN 2008 TOC-1
Table of Contents
Volume 8
Section 3 Qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

A. Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Section 4 Preparation, Calibration and Inspection . . . . . . . . . . . . . . . . . . 2-3
A. Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
B. Instrument Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Section 5 Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
A. Examination Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 6 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
A. Readout and Evaluation Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 7 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 8 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
A. Reference documents:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 9 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
A. Recurrent Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Chapter 3 Personnel Training, Qualification and Certification

Section 1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section 2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section 3 Non-Destructive Testing Methods. . . . . . . . . . . . . . . . . . . . . . . 3-2
Section 4 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
A. Certification Levels and Experience . . . . . . . . . . . . . . . . . . . . . . . 3-3
Section 5 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
A. Certification Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Section 6 Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
A. Requirements and Physical Examinations . . . . . . . . . . . . . . . . . . 3-6
Section 7 Re-certification/Recurrent Training . . . . . . . . . . . . . . . . . . . . . . 3-7
Section 8 Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Section 9 Training Outlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
A. Liquid Penetrant Training Course . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
B. Magnetic Particle Testing Training Course . . . . . . . . . . . . . . . . . . 3-9
C. Eddy Current Testing Training Course . . . . . . . . . . . . . . . . . . . . 3-11
D. Ultrasonic Testing Training Course . . . . . . . . . . . . . . . . . . . . . . . 3-13
REV. 02, 15 JUN 2008 TOC-2

Section 1 General High Frequency Eddy Current (HFEC)
Volume 8 Procedure
Chapter 1
Eddy Current Examination

Procedure
A. Scope
1. This procedure uses high frequency eddy current (HFEC) for detection of surface
cracks in metallic structures and components. Examples of areas where this
procedure can be used are as follows:
a) Cracks on flat or slightly contoured surfaces
b) Cracks propagating from an edge or cutout
c) Cracks propagating from fastener holes extending past the head or nut
end of the fasteners
d) Cracks propagating from a bearing or bushing hole
Note:These are only examples. Usage is not limited to these application.
2. Metallic materials covered by this procedure are as follows:
a) aluminum alloys
b) titanium alloys
c) 4130, 4340, 300M alloy steel and similar high permeability steels.
3. This is written to provide Chautauqua Airlines Inspectors with a written procedures

to perform an eddy current inspection to detect surface cracks in aircraft
components of the above listed materials, when no specific manufactures
procedure exists. In the event of a conflict between this procedure and any specific
manufactures procedure the manufactures procedure will take precedence.
B. Process
1. The eddy current process uses electromagnetic induction to induce eddy currents
into the test material or component. Changes in the flow of the eddy currents
caused by variations in the material or component are reflected in a nearby coil or
coils for subsequent analysis by a suitable instrument and technique.
REV. 02, 15 JUN 2008 1-1

Volume 8 Procedure
C. Equipment
1. Use the items identified as follows, or their equivalent:
Note: Equivalent eddy current equipment may be used provided that it
satisfies the requirements of this procedure and is capable of resolving
the reference notch in the calibration reference standard at the required
level of resolution.
a) Eddy current (impedance-plane type) instrument, Model: NORTEC 500S
or 2000S
b) Surface pencil probe, NORTEC PL/500 kHz-1MHz/A
c) Surface pencil probe, NORTEC ML/100kHz-500kHz/A/90.5/6
Note: To protect the probe from wear and damage, a non conductive low-
friction tape may be applied over the probe coil. The tape may require
replacement occasionally during the inspection. The non conductive
tape shall not be thicker than 0.003 in. (0.08 mm).
If the tape is to be used during inspection, it must also be used during
calibration.
d) Coaxial cable - NORTEC CL/SC/6
e) NORTEC Calibration Reference Standard No. TB-S1, made from
aluminum alloy with (29-32% IACS) and contains 0.008-inch (0.20-mm),
0.020-inch (0.51-mm) and 0.040-inch (1.02-mm) deep electrical discharge
machined (EDM) notches
f) EMBRAER Calibration Reference Standard No. 145-44131-001, made
from aluminum alloy 7050-T745 (35-40% IACS) and contains 0.008-inch
(0.20-mm), 0.020-inch (0.51-mm) and 0.040-inch (1.02-mm) deep EDM
notches
g) EMBRAER Calibration Reference Standard No. 145-44131-005, made
from titanium alloy GALY US AMS2631 CLA11/2 (1-2% IACS) and
contains 0.008-inch (0.20-mm), (0.020-inch (0.51-mm) and 0.040-inch
(1.02-mm) deep EDM notches.
h) NDT Technology Reference Standard No. SRS-0824S-4340, made from
4340 steel (MIL-S-5000), heat treat condition 180-200 KSI and contains
0.008-inch (0.20-mm), 0.020-inch (0.51-mm) and 0.040-inch (1.02-mm)
deep EDM notches
i) Flexible non conductive ruled or straight edge - commercially available
j) Non conductive draftsman type circle template - commercially available
k) Non conductive plugs or discs of various diameters - commercially avail-
able
l) High-intensity light source - commercially available
Note:The above list describes only equipment and accessories used in this
procedure.
REV. 02, 15 JUN 2008 1-2

Volume 8 Procedure
To gain access to the inspection area due to limited accessibility or

component design configuration, use a probe of different configuration, i.e.,
right angle, cranked, etc.
The test frequency used may range from 100 kHz to 2.0 MHz. For NFE
materials it is recommended that a frequency above 500 kHz be used when
it is necessary to inspect very close to an edge and a frequency below 500
kHz for rough or blended surfaces. For FE materials, it is recommended that
a frequency below 500 kHz be used.
D. Performance Verification
1. All eddy current reference standards used at Chautauqua Airlines will be properly
maintained, stored and verified periodically in accordance with Section 2
requirements. Eddy current standards shall also be tested whenever the slots
appear to be worn.
2. For maximum reliability in eddy current testing, a high signal to noise ratio is
desired. No specific signal-to-noise ratio is mandatory, but a minimum of 3 to 1 is
desirable for flaw detection.
3. Probes may be tested in accordance with the procedure outlined in Section 2.
E. Personnel Qualifications
1. Personnel performing an eddy current examination to this procedure shall be
qualified in accordance with Chautauque Airlines procedure for the qualification and
certification of Non-Destructive Testing (NDT) personnel.
2. Only tested and certified Level II, III personnel or Level I personnel that are Task
Qualified in special eddy current examinations shall interpret test results to
determine acceptability.
F. Cleaning
1. Clean the inspection area as follows:
a. Identify the location of the area to be inspected.
b. Clean the inspection surface (refer to the applicable aircraft manual for proper
cleaning procedures).
REV. 02, 15 JUN 2008 1-3

Volume 8 Procedure
G. Preparation
1. Prepare the inspection area as follows:
a. Check the surface to be inspected for any visible damage and discontinuities.
b. If the inspection area is bare or unpainted, proceed with the inspection.
Note: It is not necessary to remove the paint or primer from parts unless it
shows deterioration or local damage.
c. If the paint or primer is damaged or deteriorated, remove the finish (refer to the
applicable aircraft SRM).
d. If the inspection surface is primed, painted or has a decal, measure the coating
thickness before proceeding with the inspection.
Note: Inspection surface shall be smooth enough not to damage the probe and
to give at least a 3:1 ratio between the reference notch signal and
inspection surface noise level.
REV. 02, 15 JUN 2008 1-4

Volume 8 Procedure
H. Equipment Calibration for Inspection of Aluminum Alloy

Material
Note:Values listed in Figure 1 may vary from instrument to instrument.
INSTRUMENT SETTINGS
FREQ 250 kHz
ANGLE 124.0
H GAIN 55 dB
V GAIN 70 dB
HI FILTER OFF
LO FILTER 100
BALANCE OFF
Calibration Data
(NORTEC 2000S or 500S Eddy Current Instrument and Probe ML/100kHz-500kHz/A/90.5/6
For
Inspection of Aluminum Alloy Material
Figure 1
REV. 02, 15 JUN 2008 1-5

Volume 8 Procedure
1. Calibrate the eddy current instrument as follows:

a. Connect the pencil probe ML/100kHz-500kHz/A/90.5/6 with the coaxial cable to
the eddy current instrument.
b. Adjust and set the instrument controls as shown in Figure 1.
Note: Other frequencies and settings may be used if the requirements of this
calibration are met.
c. Determine the conductivity value in percent IACS for the aluminum alloy material
to be inspected. If the conductivity value is equal to or less than 34% IACS, use
reference standard TB-S1. If the conductivity value is greater than 34% IACS,
use reference standard 145-44131-001 for equipment calibration in step 5.A.1.d.
d. Place the probe (coil) perpendicular to the notch-free surface away from the
EDM notch of the appropriate calibration reference, TB-S1 or 145-4413-001.
e. NULL the eddy current instrument. Adjust the instrument (ANGLE) control to
obtain a horizontal lift-off signal which moves from right to left across the cathode
ray tube (CRT) display. Use the H-POS and V-POS controls to position the dot
in the lower right quadrant of the CRT display.
f. Slide the probe across the 0.040-inch (1.02-mm) deep EDM notch and adjust the
instrument sensitivity (GAIN) to obtain an amplitude signal of 80% of the vertical
scale measured from the balance point as shown in Figure 1.
g. Differentiate between the EDM notch and the edge signals by sliding the probe
(coil) over the edge of the calibration reference standard. The signal obtained
from the edge shall slant off toward the top left quadrant as shown in Figure 1.
REV. 02, 15 JUN 2008 1-6

Volume 8 Procedure
I. Equipment Calibration for Inspection of Titanium Alloy

Materials
INSTRUMENT SETTINGS
FREQ 1.0 MHz
ANGLE 71.0
H GAIN 57 dB
V GAIN 70 dB
HI FILTER OFF
LO FILTER 200
BALANCE OFF
Calibration Data
(NORTEC 2000S or 500S Eddy Current Instrument and Probe PRL/500kHz-3Mhz/D)
For
Inspection of Titanium Alloy Material
Figure 2
REV. 02, 15 JUN 2008 1-7

Volume 8 Procedure

Note: Values listed in Figure 2 may vary from instrument to instrument.
a. Connect the pencil probe PRL/500kHz-3Mhz/D with the coaxial cable to the eddy
current instrument.
c. Place the probe (coil) perpendicular to the notch-free surface away from the
EDM notch of the calibration reference standard No. 145-44131-005.
d. NULL the eddy current instrument. Adjust the instrument (ANGLE) control to
obtain a horizontal lift-off signal which moves from right to left across the CRT
display. Use the H-POS and V-POS controls to position the dot in the lower right
quadrant of the CRT display.
e. Slide the probe across the 0.040-inch (1.02-mm) deep EDM notch and adjust the
instrument sensitivity (GAIN) to obtain an amplitude signal of 60% of the vertical
scale measured from the balance point as shown in Figure 2.
REV. 02, 15 JUN 2008 1-8

Volume 8 Procedure
J. Equipment Calibration for Inspection of 4130, 4340, 300M Alloy

Steel and Similar High Permeability Steel Parts
INSTRUMENT SETTINGS
FREQ 100 kHz
ANGLE 259
H GAIN 55.0 dB
V GAIN 70.0 dB
HI FILTER OFF
LO FILTER 100
BALANCE OFF
Calibration Data
(NORTEC 2000S or 500S Eddy Current Instrument and Probe ML/100kHz-500kHz/A/90.5/6)
For
Inspection of 4130, 4340, 300M Alloy Steel and Similar High Permeability Steel Parts
Figure 3
REV. 02, 15 JUN 2008 1-9

Volume 8 Procedure

Refer to Figure 3
Note: Values listed in Figure 3 may vary from instrument to instrument.
a. Connect the pencil probe ML/100kHz-500kHz/A/90.5/6 with the coaxial cable to
the eddy current instrument.
c. Place the probe (coil) perpendicular to the notch-free surface away from the
EDM notch of the calibration reference standard NO. SRS-0824S-4340 (for high
permeability steels).
d. NULL the eddy current instrument. Adjust the instrument (ANGLE) control to
obtain a horizontal lift-off signal which moves from right to left across the CRT
display. Use the H-POS and V-POS controls to position the dot in the lower right
quadrant of the CRT display.
e. Slide and probe across the 0.040-inch (1.02-mm) deep EDM notch. The phase
angle measured between lift-off and EDM notch signals must be between 100-
120 degrees. Adjust the instrument sensitivity (GAIN) to obtain an amplitude
signal of 60% of the vertical scale measured from the balance point as shown in
Figure 3.
K. Inspection Procedure
Note: It is important to calibrate/standardize the eddy current instrument, test
probe, and reference standard prior to use, at least every 15 minutes of
continuous use and upon completion of the tests. The eddy current
equipment must be re calibrated if any part of the system is replaced or
if any control settings are changed.
1. Inspection for Cracks on Flat or Slightly Contoured Surfaces Away from the Edge
of Fasteners or Cutouts
Refer to Figure 4
a. Make sure the equipment is calibrated for the material to be inspected as
outlined in H, I or J.
b. Place the probe (coil) perpendicular to the inspection surface or suspect area.
c. REBALANCE (Null) the instrument. If necessary, adjust the instrument (PHASE)
control to obtain a horizontal lift-off signal which moves from right to left across
the CRT display with increasing lift-off.
d. Make a series of parallel scans while maintaining the probe perpendicular to the
inspection surface at all times until the entire surface is inspected. Use a scan
index no greater than one probe diameter between scans.
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Volume 8 Procedure
Note: The scan direction must be as near perpendicular to the length of the
crack as possible. If the crack direction is unknown, make another
series of parallel scans perpendicular to the first series of scans.
e. Carefully monitor the CRT display at all times and make a note of all distinct rele-
vant indications. Includes the screen height of each signal and its relative loca-
tion on the part.
Inspection for Cracks on Flat or Slightly Contoured Surfaces Away from Fasteners
Figure 4
Note: Use a non conductive straight edge as a scanning aid whenever
possible.
2. Inspection for Cracks Propagating from Edge or Cutout
Refer to Figure 5
b. Place the probe (coil) approximately 0.06 in. (1.52 mm) or as close as possible
to the edge of the part or cutout without obtaining an interference signal from the
edge, whichever is less, and position the probe perpendicular to the inspection
surface.
c. REBALANCE (Null) the instrument. If necessary, adjust the instrument (ANGLE)
the CRT display with increasing lift-off.
REV. 02, 15 JUN 2008 1-11

Volume 8 Procedure
d. Scan the full perimeter of the cutout or along the edge of the part. Maintain the
probe perpendicular to the inspection surface at all times and maintain a
constant edge distance.
vant indications. Include the screen height of each signal and its relative location
on the part.
Note: Use a non conductive straight edge as a scanning aid whenever
possible.
3. Inspection for Cracks Propagating from Fastener Holes Extending Past the Head or
Nut End of the Fasteners
Refer to Figure 6
b. Place the smallest practical size diameter hole on the circle template over the
flush head fastener so that the distance between the edge of the fastener and
the edge of the probe (coil) is approximately 0.06 in. (1.52 mm), or as close as
possible to the edge of the fastener without obtaining an interference signal from
the edge. Whichever is less?
c. Position the probe perpendicular to the inspection surface and against the inside
edge of the circle template.
Note: When inspecting the raised head or nut end of fasteners. Use the
fastener head and nut as a probe guide.
REBALANCE (Null) the instrument. If necessary, adjust the instrument (PHASE)
the CRT display.
d. Make a full circular scan around the fastener while maintaining the probe perpen-
dicular to the inspection surface at all times.
on the part.
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Volume 8 Procedure
Inspection for Cracks Propagating from an Edge Cutout

Figure 5
REV. 02, 15 JUN 2008 1-13

Volume 8 Procedure
Inspection for Cracks Propagating from Fastener Holes Extending Past the Head or Nut End of the Fasteners
Figure 6
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Volume 8 Procedure
Inspection for Cracks Propagating from Bearing Holes

or Extending Past the Bushing Flange
Figure 7
4. Inspection for Cracks Propagating from Bearing Holes or Bushing Holes or

Extending Past the Bushing Flange
a. Make sure the equipment is calibrated for the material to be inspected as outlines
in H, I or J.
b. Cover the bearing or bushing hole with a non conductive plastic disc 0.032 in.
(0.813-mm) or thicker that is the same diameter as the bearing or bushing.
c. Position the probe perpendicular to the inspection surface and against the inside
edge of the disc.
d. REBALANCE (Null) the instrument. If necessary, adjust the instrument (PHASE)
control to obtain a horizontal lift-off which moves from right to left across the CRT
display.
REV. 02, 15 JUN 2008 1-15

Volume 8 Procedure
e. Make a full circular scan around the bearing or bushing hole using the plastic disc
as a probe guide while maintaining the probe perpendicular to the inspection
surface at all times.
f. Carefully monitor the CRT display at all times and make a note of all distinct rele-
on the part.
Note: When inspecting the flanged side of the bushing, use the flange as a
probe guide.
L. Evaluation of Indications
1. Evaluate indications as follows:
a. Any distinct vertical deflection signal that occurs over a short scan distance (one
probe tip diameter) is considered as a suspect indication and cause for further
evaluation. A crack indication will be similar to the EDM notch indication signal
which is equal to 50% or greater than the response from the 0.040-inch (1.02
mm) deep EDM notch should be classified as a crack.
b. Ensure the indication is not caused by edge effect, abrupt change in geometry,
localized variations in conductivity, or other non relevant factors.
c. Evaluate all crack indications by comparing their phase angle, amplitude, and
shape to the calibration notch signal.
d. If a crack is detected, determine the crack length.
M. Acceptance or Rejection Criteria

1. All relevant indications shall be accepted or rejected based on the applicable aircraft
SRM. When no definitive SRM data exists, the applicable Aircraft Manufacture’s
Technical Support Department in conjunction with Chautauqua Airlines Engineering
Department will be contacted for disposition.
REV. 02, 15 JUN 2008 1-16

Section 2 Eddy Current Process Control
Volume 8
A. Scope
1. The following is written to provide a procedure for determining the serviceability of
eddy current probes and standards used at Chautauqua Airlines.
Note: For maximum reliability in ET, a high signal-to-noise ratio is desired. No
specific signal-to-noise ratio is mandatory, but a minimum of 3-to-1 is
desirable for flaw detection.
B. Equipment
1. Use the items identified as follows, or their equivalent:.
a. Eddy current (impedance-plane type) instrument, Model: NORTEC 2000S
C. Personnel Qualifications
1. Personnel performing an eddy current examination to this procedure shall be
qualified in accordance with Chautauqua Airlines procedure for the qualification and
2. Only tested and certified Level II, III personnel shall perform eddy current process
control.
D. Probe Test
1. The following steps are designed for testing eddy current probes:
a. Attach probe and cable to the proper connector.
Note: If using a BNC or Bumdy cable on the NORTEC 2000S, use the
Balancing Coil. A Balancing Coil is not required for the NORTEC 500S.
The coil is built into the instrument. Make sure the coil switch is on
“LOW” for 50 Hz-100 kHz probes or “HI” for 100 kHz 500 kHz probes. If
using a LEMO cable or LEMO to BNC adapter, connect directly to the
instrument.
b. Place Teflon tape across the three surface slots on the eddy current standard.
c. Turn on the unit by pressing the green circular button. When the unit is first
turned on it will display the “DIAGNOSTICS” self-test and the last setup program
that was used.
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Volume 8
STEPS d. - j. loads the “DEFAULT” program

d. Press the [SETUP/SPECIAL] button until the “set up” menu appears. the “setup”
menu displays REPORT CLOCK DEFAULT in the top row.
e. Press the 3rd soft key [^] until DEFAULT is highlighted.
f. Press the [ENTER] button.
g. Press the 4th soft key [^] to select LD DEFLT. there should be 3 highlighted
areas: LD DEFLT lower right side above the 4th soft key [^], LD DEFLT 4th row
in right column, and DEFAULT above 5th soft key [^].
h. Press the [ENTER] button.
Note: A 4th highlighted LD DEFLT will be displayed above the function row. To
the right of the highlighted LD DEFLT there will be either CANCEL or
CONFIRM.
i. Rotate the SMARTKNOB until it reads CONFIRM.
j. Press the [ENTER] button.
Note: The “DEFAULT” program is now loaded. The MAIN menu display should
be in “flying dot” mode. The following values should be displayed.
FREQUENCY 100 kHz
ANGLE 0
H-GAIN 40.0 dB
V-GAIN 40.0 dB
PROBE DRIVE MID
k. FREQUENCY should be highlighted; if not, press 1st soft key [^].
l. Rotate SMARTKNOB to set the minimum frequency identified on the probe.
m. Press the 3rd soft key [^].
Note: GAIN should be highlighted above the soft key and both the H-GAIN and
V-GAIN should be highlighted on the right side.
n. Place the probe on the Teflon tape away from slot and “null” the instrument by
pressing the [NULL] button.
o. Press the [ERASE] button.
Note: After “Nulling” the instrument it is always a good practice to press the
[ERASE] button after pressing the [NULL] button. This clears the display
and places the “flying dot” at the center position.
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Volume 8
p. Press the 2nd soft key [^]. ANGLE should be highlighted in two places.
q. Scan over the 0.040 inch slot while rotating the SMARTKNOB to adjust phase
angle. The “flying dot” should be rotated to a vertical position.
r. Press the 3rd soft key [^]. (See step m. note.)
s. While scanning the 0.040 inch slot, rotate the SMARTKNOB until the response
from the crack moves the dot exactly three square division. To improve gain
control use the [ERASE] button occasionally to clear the display.
t. Record the gain setting for that frequency.
u. Repeat the steps j. through u. to achieve a low, medium (Pick a number that is
in-between the low and high), and high frequency reading for each probe. (e.g.,
60.3 at 50 kHz for a low frequency. 53.2 at 200 kHz and 59.6 at 500 kHz.)
Note: Some probes have their frequency range (low to high frequencies)
identified on the probe handle. Others may not. If the probe frequency
range is not identified, use 200 kHz, 500 kHz, or l MHz. The “flying dot”
will not behave properly when the probe’s frequency range is exceeded
(either low or high). The dot should be relatively stable after “nulling” the
instrument. There should be a definite response displayed when the
0.040 inch slot is scanned. If not, try another frequency. The optimum
frequency for the probe is the frequency with the lowest gain setting and
highest signal response. Probes may be tested after receiving them and
periodically (based on use) thereafter. If the readings are by 20% or
more the next time you test the probe, it should be replaced.
E. Standard Slot Test

1. The following steps are designed for testing eddy current standards. This test is
applicable to flat EDM slot standards. Other standards used by Chautauqua Airlines
Inspectors for eddy current calibration will receive a visual inspection for wear,
corrosion or damage at the same recurrent interval as flat EDM slot standards.
2. All standards shall be initially inspected and then reinspected at an interval not to
exceed one year from the date put in service.
3. All eddy current standards will be tracked in the Chautauqua Airlines system as
calibrated tools.
4. Standards that fail visual or slot test shall be removed from service and replaced.
REV. 02, 15 JUN 2008 1-19

Volume 8
5. Flat EDM slot standard test:

Note: If using a BNC or Burndy cable on the NORTEC 2000S, use a Balancing
Coil. A Balancing Coil is not required for the NORTEC 500S. The coil is
built into the instrument. Make sure the coil switch is on “LOW” for 50
Hz-100 kHz probes or “HI” for 100 kHz-500 kHz probes. If using a
LEMO cable or LEMO to BNC adapter, connect directly to the
instrument.
a. Place Teflon tape across the four surface slots on the eddy current standard.
b. Turn on the unit by pressing the green circular button. When the unit is first
turned on it will display the “DIAGNOSTICS” self test and the last setup program
that was used.
STEPS d. - l. loads the “DEFAULT” program.
c. Press the [SETUP/SPECIAL] button until the “setup” menu appears. The “setup”
menu displays REPORT CLOCK DEFAULT in the top row.
d. Press the 3rd soft key [^] until DEFAULT is highlighted.
e. Press the [ENTER] button.
f. Press the 4th soft key [^] to select LDDEFLT. There should be three highlighted
areas: LD DEFLT lower right side above the 4th soft key [^], LD DEFLT 4th row
in right column, and DEFAULT above 5th soft key [^].
g. Press the [ENTER] button.
Note: A 4th highlighted LD DEFLT will be displayed above the function row. To
the right of the highlighted LD DEFLT there will be either CANCEL or
CONFIRM.
h. Rotate the SMARTKNOB till it read-, CONFIRM.
i. Press the [ENTER] button.
Note: The “DEFAULT” program is now loaded. The MAIN menu display should
be in “flying dot” mode. The following values should be displayed.
FREQUENCY 100 KhZ
ANGLE 0
H-GAIN 40.0 dB
V-GAIN 40.0 dB
PROBE DRIVE MID
j. FREQUENCY should be highlighted; if not, press 1st soft key [^].
k. Rotate SMARTKNOB to set the frequency at 500 kHz.
l. Press the 3rd soft key [^].
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Volume 8
Note: GAIN should be highlighted above the soft key and both the H-GAIN and
V-GAIN should be highlighted on the right side.
m. Rotate the SMARTKNOB to set the gain at 50 dB horizontal and 50 dB vertical.
n. Place the probe on the Teflon tape away from slot and “null” the instrument by
pressing the [NULL] button.
o. Press the [ERASE] button.
Note: After “nulling” the instrument it is always a good practice to press the
[ERASE] button after pressing the [NULL] button. This clears the display
and places the “flying dot” at the center position.
p. Press the 2nd soft key [^]. ANGLE should be highlighted in two places.
q. Scan over the 0.040 inch slot while rotating the SMARTKNOB to adjust phase
angle. The “flying dot” should be rotating to a vertical position.
r. Press the 3rd soft key [^]. (See paragraph D.1. Step m. note.)
s. While scanning the 0.040 inch slot, rotate the SMARTKNOB until the response
from the crack moves the dot exactly three square divisions. To improve gain
control, use the [ERASE] button occasionally to clear the display.
t. Place a straight edge (ruler, triangle edge, etc.) adjacent to and inline with the
notch so that the probe’s center is on the center of the notch.
u. Press the [ERASE] button so that the dot is showing at three divisions.
v. Move the probe down the slot lengthwise using the straight edge as a guide.
w. The dot should not move more than 1/10th of an division until it comes to the
edge of the standard or the edge of the slot (Edge Effect).
x. Repeat the steps m. through u. for the 0.020,” and 0.008” slots. Remember the
gain will have to be increased to align the dot at three divisions.
Note: For the 0.008” slot. use one division instead of three divisions.
REV. 02, 15 JUN 2008 1-21

Volume 8
REV. 02, 15 JUN 2008 1-22

Section 1 Contact Ultrasonic
Volume 8
Chapter 2
Ultrasonic
Section 1 Contact Ultrasonic
A. Scope
1. The purpose of this procedure is to cover the requirements for Contact Ultrasonic
(UT) examination of materials and aircraft components for defects and material
thickness.
2. This procedure covers the use of straight beam (longitudinal) and angle beam
(shear wave) contact ultrasonic examination methods, including pulse-echo and
through transmission techniques to detect and measure material thickness in
aircraft components.
B. Process
1. The ultrasonic process uses a series of electrical pules applied to a piezoelectric
element (transducer) which converts these pulses to mechanical energy in the form
of pulsed wave at a nominal frequency. The transducer is mounted in holder so it
can transmit the waves into the test material or component through a suitable wear
surface and component. With this search unit the Pulsed energy is transmitted into
materials, travels in a direction normal to the contacted surface, and is reflected
back to the search unit, where they are converted back to an electrical impulse sent
to the ultrasonic unit and displayed for evaluation on the A-scan display. From this
display different types of information may be obtained such as, apparent defect
size, depth of the defect, certain material properties, material thicknesses, and the
extent of bond and un-bond if geometry and material permit.
2. Chautauqua Airlines uses the process specified in this procedure or those specified
by aircraft manufacture’s requirements or directives.
REV. 02, 15 JUN 2008 2-1

Section 2 Equipment and Verification
Volume 8
Section 2 Equipment and Verification
A. Equipment
1. Chautauqua Airlines uses ultrasonic instrumentation capable of generating,
receiving, and amplifying high-frequency electrical pulses at such frequencies and
energy levels required to perform a meaningful examination and to provide a
suitable readout. The ultrasonic unit currently in use at Chautauqua Airlines is the
Sonic 1200HR+. Specifications and capabilities of this unit are on file at
Chautauqua Airlines.
2. Various types of ultrasonic search units will be used that are capable of transmitting
and receiving ultrasound in the material at the required frequencies and energy
levels necessary for discontinuity detection. Typical search unit sizes usually range
from 1/8 in. in diameter to 11/8 in. in diameter with both smaller and larger sizes
available for specific applications.
3. Search units may be fitted with special shoes for appropriate applications such as
thin wall material.
4. Search units for angle-beam examination may be “potted” type or may be fitted with
special angled shoes for appropriate applications as well.
5. A Couplant, usually a liquid or semi-liquid, is required between the face of the

search unit and the examination surface to permit or improve the transmittance of
ultrasound from the search unit into the material under examination. Any couplant
that is adequate to provide an air-free acoustical coupling between the search unit
and the component and is not detrimental to the component being examined will be
utilized unless a specific type or brand of couplant is specified per the aircraft
manufacturer’s requirements or directives.
6. Test standards, either generic, such as an IIW block, or specific to aircraft
manufacture’s requirements or directives are utilized to set up for each inspection
performed. Requirements for customer specific test standards must be obtained
before performing the examination. The test standard and the component being
examined should be acoustically similar in velocity and attenuation.
7. The test standard will have the same geometry as the component being examined.
B. Performance/Equipment Verification
1. The ultrasonic unit will be sent to the manufacturer once every 12 months for
calibration.
2. The manufacturer’s certification for each search unit are to be kept on file at
Chautauqua Airlines.
3. The exit point and exit angle of ultrasonic energy and depth profile of the sound
beam will be established for angle-beam search units. Search units with beam
angles departing more then +3 degrees from the manufacturer’s indicated values
shall not be used.
REV. 01, 01 MAR 2008 2-2

Section 3 Qualifications
Volume 8
Section 3 Qualifications
A. Personnel Qualifications
1. Personnel performing ultrasonic examination to this procedure will be qualified in
accordance with Chautauqua Airlines procedures for the qualification and
2. Only tested and certified Level 2 or 3 personnel or level I personnel that are Task
Qualified in specific contact ultrasonic examination will interpret test results to
determine acceptability.
Section 4 Preparation, Calibration and Inspection
A. Surface Preparation
1. Attain access to inspection area if inspection is being performed on aircraft.
2. Remove loose paint, dirt and sealant from the surface of the inspection area.
B. Instrument Standardization
1. Straight beam or angle beam ultrasonic examination will be set-up as follows to
insure the detection of recordable discontinuities or as specified by the aircraft
manufacturer's requirements or directives.
2. Select a suitable search unit size and frequency after consideration of the acoustic
characteristics of the material to be examined, the geometry of the component, and
the minimum size and type of discontinuity to be detected. The specific search unit
designated by the aircraft manufacturer's requirements or directives shall be used
where specified.
3. Select the best test standard that will give the most favorable response for the test
being performed. Specific test standards designated by the aircraft manufacturer's
requirements or directives will be used where specified.
4. Place a thin even layer of couplant on the test standard in the area of interest. Place
the search unit on the area of interest and attain a response that will insure detection
of all relevant discontinuities. If specified in the aircraft manufacturer's requirements
or directives attain the response that is required to the specific test standard. (see
7.9)
REV. 01, 01 MAR 2008 2-3

Section 4 Preparation, Calibration and Inspection
Volume 8
5. For straight beam exams the initial pulse and at least one back reflection will appear
on the A-scan display unless otherwise specified in the aircraft manufacturer’s
requirements or directives. (see 7.9)
6. For bond/un-bond examinations, a test standard shall be used similar the

component being examined containing area representing both bonded and un-
bonded conditions. (see 7.9)
7. For angle-beam exams an IIW type inspection test standard can be used to set up
for distance standardization and angle verification or as specified in the aircraft
manufacturer’s requirements or directives. The sound beam entry angle shall not
vary more than ±3 degrees from the established angle for that search unit. (see 7.9)
8. This block may also be used for amplitude standardization.

9. A specific test standard per the aircraft manufacturer’s requirements or
directives shall be used when specified.
10. Maximum scanning speed and scanning index should be determined at this time.
Maximum scanning speed will be that which the reference discontinuities shall be
clearly discernible or as specified by the aircraft manufacturer’s requirements or
directives. The maximum speed will not exceed three inches per second, and the
scan index shall be no more than 10 percent or that which is specified in the aircraft
manufacturer's requirements.
11. Once the instrument has been standardized with these methods or those specified
in the aircraft manufacturer's requirements or FAA directives the examination can
begin.
12. The instrument standardization will be performed as follows:

• -Immediately prior to starting an examination
• -Whenever an examination has been interrupted by the equipment
• being turned off or left unattended by the inspector.
• -Whenever the inspector has reason to suspect that conditions affecting the
instrument standardization have changed.
• -When in use, at least every four hours.
13. Any examinations being performed will be standardized in accordance with aircraft
manufacturer's requirements or directives specific to that examination.
REV. 01, 01 MAR 2008 2-4

Section 5 Examination
Volume 8
A. Examination Procedure
1. Before the examination begins, a visual examination will be performed on the area
to be examined to ensure that the sound beam entry surfaces are free from loose
paint, or other surface conditions that could interfere with the sound beam and affect
the exam.
2. Apply a thin even layer of couplant.
3. Place the search unit on the examination surface in the area of interest or at the best
location to start the examination.
4. Slowly make a scan of the examination area and monitor the instrument display
during the scan.
5. For straight beam examination look for the initial pulse and at least one back
reflection or a signal as required by the aircraft manufacturer's requirements or
directives.
6. For angle beam examination the response will be as required by the aircraft
manufacturer's requirements or directives.
7. During the examination, maximum scanning speed shall no faster than was
determined during the standardization of the instrument.
8. During the examination it may be acceptable to increase the gain of the instrument
by 6db above the reference level before examination to aid in the detection of
discontinuities. This is provided the added sensitivity does not increase the noise
level by more than 50 percent of the recordable indication height. The requirements
of the aircraft manufacturer's requirements or directives shall take precedence.
9. For any special scanning technique, instrument set-up or search unit location for
specific examinations, refer to aircraft manufacturer's requirements or directives for
that inspection.
Section 6 Evaluation
A. Readout and Evaluation Criteria

1. During the examination any indications that exceed the reference level will be
evaluated.
2. All relevant indications or signals will be evaluated to the acceptance standards

specified by the aircraft manufacturer’s requirements or FAA directives.
3. The aircraft manufacturer's requirements or directives will have the final authority
and responsibility for interpretation and acceptance of all ultrasonic examination
results.
REV. 01, 01 MAR 2008 2-5

Section 7 Reports
Volume 8
Section 7 Reports
If required at completion of the inspection the inspector will complete the Chautauqua
Non-Routine GMM Form 102C or those forms as required by the aircraft manufac-
turer's requirements or directives.
Section 8 Reference Documents
A. Reference documents:
1. AMS 2630Ultrasonic Inspection for product over 0.5 Inch Thick
2. AMS 2632Ultrasonic Inspection for Product Under 0.5 Inch Thick

3. ASTM E114Standard Practice for Ultrasonic Pulse-Echo Straight-Beam
Examination By the Contact Method
4. ASTM E587Standard Practice for Ultrasonic Angle-Beam Examination by the

Contact Method
5. Chautauqua Airlines - Qualification and certification of NDT Personnel
Section 9 Training
A. Recurrent Training
See Chapter 3, Section 7 of the Chautauqua Airlines NDI manual.
REV. 01, 01 MAR 2008 2-6

Section 1 Purpose
Volume 8
Chapter 3
Personnel Training, Qualification and
Certification
Section 1 Purpose
These procedures establish minimum requirements for the training, qualification and
certification of personnel conducting Nondestructive Testing (NDT).
These procedures meets or exceeds the requirements of ATA 105.
Section 2 Definitions
Certification Written testimony of qualification.
Certifying Agency The employer of the personnel being certified.
Grandfathered Certification of individuals who are considered
qualified under a prior qualification program.
Instructor The instructor shall meet the requirements of a Level
II and have the necessary skills and knowledge to
plan, organize, and present classroom, laboratory,
or on-the-job training programs of instruction in
accordance with approved course outlines, in the
method for which certified. The individual shall be
thoroughly familiar with the theory and practical
applications of the method as utilized by the
employer. The individual shall not conduct
nondestructive testing for the acceptance of parts
unless he or she is properly qualified.
On-the-Job Training (OJT) Training, during work time, in learning
instrumentation set up, equipment operation,
recognition of indications, and interpretation under
the technical guidance of an experienced Level II,
Level III, or other designated individual.
REV. 01, 01 MAR 2008 3-1

Section 3 Non-Destructive Testing Methods
Volume 8
Outside Agency The organization under contract for NDT services,

which may include an examination of personnel to
the requirements of this standard. Consultants and
self-employed individuals are included in this
definition.
Qualification Demonstrated skill, training, knowledge and
experience required for personnel to properly
perform the duties of a specific job.
Recertification/
Recurrent training Scheduled, periodic classroom training, on-the-job
training or the combination of both, with the purpose
of refreshing knowledge and/or expanding the skills
of individuals in a specific NDT method. This training
is beyond initial training. This training is to be
delivered under the guidance of a qualified
instructor, Level II, Level III, or other designated
individuals in the same method.
Training The program developed to impart the knowledge
and skills necessary to qualify.
Trainee An Individual participating in a training program for
an NDT method who is not certified. Trainees shall
obtain work experience only under the direct
supervision of a qualified instructor, Level II or Level
III in the same method. Trainees shall not
independently conduct tests, make accept or reject
decision, or perform any other NDT functions.
Section 3 Non-Destructive Testing Methods

Qualification of personnel in accordance with this specification shall be applicable to
the following methods:
• Liquid Penetrant Testing (PT)
• Magnetic Particle Testing (MT)
• Eddy Current Testing (ET)
• Ultrasonic Testing (UT)
REV. 02, 15 JUN 2008 3-2

Section 4 Qualification
Volume 8
Section 4 Qualification
A. Certification Levels and Experience

1. An NDT individual must have sufficient training and experience and possess an
Airframe and/or Powerplant License or Repairman Certificate as required by the
certificate holder to properly perform the necessary tasks.
2. An NDT individual shall be qualified to direct and perform tests in the method
concerned. The individual must also be able to set up and calibrate equipment
(where applicable), read and interpret indications and evaluate them with reference
to applicable standards and specifications. The individual shall be thoroughly
familiar with the scope and limitations of the method and shall have the ability to
apply detailed techniques to products or parts within the limit of the qualifications.
They shall be able to organize and report nondestructive testing results.
3. Personnel presently qualified to perform specific methods of NDT may request

Level I or Level II certification. By presenting documentation of previous training and
experience as previously required by the employer for each NDT method to the
Qualified Level III, and individual may be grandfathered to the requested level.
Permanent personnel records shall indicate when and individual has been
grandfathered.
4. There are three basic levels of NDT personnel qualification.
5. Level I (Task Specific Qualified)

The Level I certification or Task Qualification shall be for a specified method or tech-
nique. The individual shall have the skills and knowledge to perform specific tests,
specific calibrations, specific interpretations and evaluations for acceptance or
rejection, and document the results in accordance with specific procedures. The
individual shall be knowledgeable of any necessary preparation of parts before or
after inspection. The individual shall be able to follow procedures in the techniques
for which qualified and shall receive necessary training and guidance from a quali-
fied Level II or Level III for task qualification. The individual shall meet the require-
ments of table 1.
6. Level II
The Level II individual shall have the skills and knowledge to set up and calibrate
equipment, conduct tests, and to interpret, evaluate, and document results in accor-
dance with procedures in all techniques utilized by Chautauqua Airlines in the
method certified. The individual shall be thoroughly familiar with the scope and limi-
tations of the method to which they are certified and shall be capable of providing
on-the-job training for level I personnel and other inspectors. The individual shall be
able to organize and document NDT results. The individual shall be familiar with the
codes, standards, and other documents that control the method as utilized by Chau-
tauqua Airlines. The individual shall also be qualified to perform Task Qualifications
for Level I personnel as directed by the Quality Control Manager or responsible
Level III. The individual shall meet the requirements of Table 1.
REV. 01, 01 MAR 2008 3-3

Section 5 Requirements
Volume 8
7. Level III
The Level III individual shall have the skills and knowledge to interpret codes, stan-
dards, and other regulatory documents that control the method as utilized by Chau-
tauqua Airlines; select the method and technique for specific inspection; select and/
or design equipment and reference standards; and verify the adequacy of proce-
dures. Only individuals certified to this qualification shall have the authority to
approve procedures for technical adequacy in the method to which they are certi-
fied. The individual shall also have general knowledge of all other NDT methods
utilized by Chautauqua Airlines. The individual shall be capable of conducting or
directing the training and examination of personnel in the method certified.
A. Certification Criteria
To be considered for certification, a candidate shall satisfy one to the following criteria
for the applicable NDT skills:
1. Level I / Level II
(See Table 1)
2. Level III
(A) Have graduated from a minimum four-year college or university curriculum with
a degree in engineering or science, plus one year minimum experience in NDT
testing in an assignment comparable to that of an NDT level II in the applicable NDT
method(s); or
(B) Have completed two years of engineering or science study at a university,
college, or technical school, plus two years’ experience in assignments at least
comparable to that for NDT Level II in the applicable NDT method(s); or
(C) Have four years’ experience in an assignment at least comparable to that of an
NDT Level II in the applicable NDT method(s).
3. Records of qualification and certification are maintained by Chautauqua Airlines.
4. A qualified outside agency may be engaged to provide NDT training and

Qualification.
REV. 01, 01 MAR 2008 3-4

Volume 8
NDT METHOD LEVELS
CLASSROOM INSTRUCTION EXPERIENCE (HRS./ MO.)2

(HRS.)
Level I Level I Level II1
LIQUID PENETRANT 16 160 / 1 mo.4 480 / 3 mo.
MAGNETIC PARTICLE 20 160 / 1 mo.4 480 / 3 mo.
EDDY CURRENT 40 480 / 3 mo. 1440 / 9 mo.
ULTRASONIC 40 480 / 3 mo. 1440 / 9 mo.
NOTES:
1) A Level I may be certified to Level II after satisfactory completion of required
experience in method certified.
2) Initial certification may be gained simultaneously in two or more methods if:
a) The candidate spends a minimum of 25 percent of work time on each
method for which certification is sought, and
b) The remainder if work time claimed as experience is spent in NDT-related
activities.
3) During the first 90 days, the individual shall independently accomplish only
procedures that they have previously been on-the-job qualified. Documenta-
tion is required.
4) The experience for Magnetic Particle and Penetrant can be reduced to 80
hours (two weeks) where the inspector holds an Airframe or Powerplant
license or repairman certificate.
5) An individual who has met the minimum requirements of the 40 hour course
for Eddy Current or Ultrasonic can be Task Qualified to perform a basic
surface scan or specific Eddy Current or Ultrasonic inspections as required by
the proper authority. This qualification may be performed by a Level II or the
Level III. The individual shall have a minimum of three hours training to
perform the specific task.
6) An individual who has met the minimum requirements of the 16 hour course
for penetrant may be Task Qualified to perform specific penetrant inspectors
as required by the proper authority. This qualification may be performed by a
Level II or the Level III. The individual shall have a minimum of three hours
training to perform the specific tasks.
REV. 02, 15 JUN 2008 3-5

Volume 8
A. Requirements and Physical Examinations

1. To be considered for certification/recertification, personnel must meet the
requirements of Section 5.0.
2. The physical examination shall assure that the applicants near vision and color
perception meet the following requirements.
3. Physical Examinations
a. Near-vision shall be such that personnel can read Snellen equivalent 20/25 with
at least one eye either corrected or uncorrected.
b. Distance-vision shall be such that personnel can read Snellen equivalent 20/50
with at least one eye either corrected or uncorrected.
c. These examinations shall be administered at initial certification and on a periodic
basis not to exceed 2 years.
d. Color perception shall be such that personnel can differentiate and distinguish
between colors used in the method for which certification is sought. This exami-
nation shall be administered at initial certification and on a periodic basis not to
exceed 2 years.
4. General Examinations
a. The general exam for all skill levels shall be a closed-book exam consisting of
questions that cover the basic test principles relative to the applicable method
and equipment, operating procedures and test techniques that personnel may
encounter in their assignment.
b. A minimum of 40 questions shall be used to cover pertinent information covering
the applicable method and shall also include questions covering equipment,
specifications and/or standards used by Chautauqua Airlines in NDT proce-
dures.
5. Practical
a. A part of the classroom training, personnel being considered for qualification
shall satisfactorily demonstrate that they are familiar with and can operate
necessary test equipment and interpret the resultant information to the degree
required by the Level III or other qualified individual.
b. OJT/Shop experience shall be accomplished in the shop area on actual aircraft
components under normal working conditions. The hours are defined in 5.1.5,
Table 1, or may be determined by previous documented experience.
c. Upon satisfactory completion of the Physical, General and Practical require-
ments personnel shall be certified in accordance with 5.1.5, Table 1.
REV. 02, 15 JUN 2008 3-6

Section 7 Re-certification/Recurrent Training
Volume 8
6. Examinations and Grading

a. A Level III or qualified examiner designated by Chautauqua Airlines shall
conduct and grade the qualification exams for each classification.
b. Exams administered for qualification shall result in a composite score of at least
80 percent, with no individual exam having a grade less that 70 percent.
c. Personnel failing the exams, at the discretion of Chautauqua Airlines, may be
given time for additional studies and re-examined. The re-examination shall not
utilize the same questions or specimens that were used in the initial examina-
tions.
Section 7 Re-certification/Recurrent Training

Personnel shall be required to be retrained or re-examined and their certification con-
tinued or revoked at the discretion of Chautauqua Airlines when they:
• Demonstrate unsatisfactory performance.
• Have been inactive in the method for a six-month period.
• Fail to comply with Section 6
Personnel shall receive recurrent training and be evaluated for compliance with perfor-
mance standards, by a Level III or other designated individual, at an interval not to
exceed three years.
Section 8 Records
Chautauqua Airlines will maintain individual personnel training records for as long as
their certification is in effect. These records will be available for audit by authorized per-
sonnel or agencies.
REV. 01, 01 MAR 2008 3-7

Section 9 Training Outlines
Volume 8

The entire body of knowledge contained in these training outlines for the applicable
method shall be covered in the training course. Each method taught shall consist of
basic classroom training instruction and appropriate practical demonstrations and/or
OJT to ensure complete understanding.
A. Liquid Penetrant Training Course

1. Introduction
a. Brief history of NDT and liquid penetrant testing
b. Purpose of liquid penetrant testing
c. Basic principles of liquid penetrant testing
d. Types of liquid penetrants commercially available
2. Liquid Penetrant Processing

a. Preparation of parts
b. Application of penetrant to parts
c. Removal of surface penetrant
d. Developer application and drying
e. Inspection and evaluation
f. Post-cleaning
3. Selection of Penetrant Test Methods
a. Advantages of various methods
b. Disadvantages of various methods
4. Liquid Penetrant Test Equipment

a. Liquid penetrant test units
b. Lighting for liquid penetrant inspection
c. Materials for liquid penetrant inspection
d. Precautions in penetrant inspection
REV. 01, 01 MAR 2008 3-8

Volume 8
5. Liquid Penetrant Indications

a. General
b. Factors affecting indications
c. Establishing acceptance standards
d. Indications from cracks
e. Indications from laminar discontinuities
f. Indications from porosity
g. Non-relevant indications
6. Inspection Procedures and Standards
a. ASTM E1417
b. Chautauqua specific procedures
7. Final Written/Practical Examination
(Total Time – 16 hours)
B. Magnetic Particle Testing Training Course

1. Principles of Magnets and Magnetic Fields
a. Theory of magnetic fields
b. Theory of Magnetism
c. Terminology associated with magnetic particle testing
2. Characteristics of Magnetic Fields

a. Bar magnet
b. Ring magnet
3. Effect of Discontinuities on Materials

a. Surface Cracks
b. Scratches
c. Subsurface defects
4. Magnetization by Means of Electric Current

a. Circular field
b. Longitudinal field
REV. 01, 01 MAR 2008 3-9

Volume 8
5. Selecting the Proper Method of Magnetization

a. Alloy, shape and condition of part
b. Type of magnetizing current
c. Direction of magnetic field
d. Sequence of operation
e. Value of flux density
6. Inspection Materials
a. Wet particle
b. Dry particles
7. Principles of Demagnetization
a. Residual magnetism
b. Reasons for requiring demagnetization
c. Longitudinal and circular residual field
d. Basic principles of demagnetization
e. Retentivity and coercive force
f. Methods of demagnetization
8. Magnetic Particle Test Equipment

a. Equipment selection considerations
b. Manual inspection equipment
c. Medium and heavy duty equipment
d. Stationary equipment
e. Mechanized inspection equipment
9. Types of Discontinuities Located by Magnetic Particle Testing

a. Inclusions
b. Blowholes
c. Porosity
d. Flakes
e. Cracks
f. Pipes
g. Laminations
h. Laps
i. Forging bursts
j. (10) Voids
REV. 01, 01 MAR 2008 3-10

Volume 8
10. Magnetic Particle Test Indications and Interpretations

a. Indications of nonmetallic inclusions
b. Indications of surface seams
c. Indications of cracks
d. Indications of laminations
e. Indications of laps
f. Indications of bursts and flakes
g. Indications of porosity
h. Nonrelevant indications
11. Final Written/Practical Exam
C. Eddy Current Testing Training Course

1. Introduction
a. Brief history of eddy current testing
b. Basic principles of eddy current testing
2. Eddy Current Theory

a. Generation of eddy currents by means of an AC field
b. Effect of fields created by eddy currents (impedance changes)
c. Effect of change of impedance on instrumentation
d. Properties of eddy current
3. Types of Sensing Elements

a. Probes
b. Through, Encircling, or Annular Coils
c. Factors affecting choice of sensing elements
4. Factors Which Affect Coil Impedance
a. Test part
b. Test System
5. Signal / Noise Ratio

a. Definition
b. Relationship to eddy current testing
c. Relationship to flux leakage testing
d. Methods of improving signal / noise ratio
REV. 01, 01 MAR 2008 3-11
Volume 8
6. Selection of Test Frequency

a. Relationship of frequency to type of test
b. Considerations affecting choice of test
7. Coupling
a. “Fill-factor” in through-coil inspection
b. “lift-off” and compensation in probe coil inspection
8. Field Strength and its Selection

a. Permeability changes
b. Saturation
c. Effect of a-c field strength on eddy current testing
9. Instrument Design Consideration

a. Amplification
b. Phase discrimination
c. Differential or filtering
10. Read-Out Mechanism

a. Calibrated or non-calibrated meter
b. Null meter with dial indicator
c. Oscilloscope
d. Alarm, Lights, etc.
e. Sorting gates and tables
f. Strip chart recorder
11. Applications
a. Flaw detection
b. Sorting for properties related to conductivity
c. Sorting for properties related to permeability
d. Thickness evaluation
e. Measurement of magnetic characteristic values
12. Reference Standards and Operating Procedures
a. Explanation of standards and specifications used in eddy current testing
b. Explanation of operating procedures used in eddy current testing
13. Final Written / Practical Examination

REV. 01, 01 MAR 2008 3-12

Volume 8
D. Ultrasonic Testing Training Course

1. Fundamental Properties of Sound
a. Frequency, velocity and wavelength
b. Definition of ultrasonic vibrations
c. General application of ultrasonic vibrations
2. Principles of Wave Propagation

a. Modes of vibration
b. Acoustic impedance
c. Reflection
d. Refraction and mode conversation
e. Diffraction and mode conversation
f. Fresnel and Fraunhofer effects
3. Generation of Ultrasonic Waves

a. Piezoelectricity and types of crystals
b. Construction of ultrasonic search units
c. Characteristics of search units
1) Frequency-crystal thickness relationships
2) Conversion efficiencies of various crystals
3) Damping and resolution
4) Beam intensity characteristics
4. Care of search units
5. Ultrasonic Testing Methods
a. Contact testing
1) Straight beam
2) Angle beam
3) Surface wave
4) Lamb wave
5) Through transmission
b. Immersion testing
1) Straight beam
2) Angle beam
3) Through transmission
c. Modified immersion testing
1) Tests employing special devices
REV. 02, 15 JUN 2008 3-13

Volume 8
6. Ultrasonic Testing Equipment

a. Description of basic pulse-echo instrument
1) Time-base (synchronizer) circuit
2) Pulser circuit
3) Receiver or echo-amplifier circuit
4) A-Scan display unit
b. Special Instructions
1) B-Scan display
2) C-Scan display
3) Monitors and recording
c. Scanning equipment
1) Manipulators
2) Bridges
3) Special scanning devices
d. Ultrasonic bond test equipment
7. Specific Testing Procedures

a. Selection of tests parameters
1) Frequency
2) Search unit size and type
3) Water distance (for immersed tests)
4) Scanning speed and index
b. Test standardization
1) Ultrasonic standard reference blocks
2) Adjustment of test sensitivity
c. Interpretation of results
1) Acceptance standards
2) Comparison between responses from discontinuities to those from ultrasonic
reference standards
3) Estimated length of discontinuities
4) Location of discontinuities
5) Zoning
d. Equipment performance variations
REV. 02, 15 JUN 2008 3-14

Volume 8
8. Variables Affecting Test Results

a. Instrument performance variations
b. Search unit performance variations
c. Inspected part variations
1) Entry surface condition
2) Part size and geometry
3) Metallurgical structure
d. Discontinuity variations
1) Size and geometry
2) Distance location from entry surface
3) Orientation to entry surface
4) Type of discontinuity-reflecting characteristics
9. Final Written / Practical Examination
Total Time (Hours) 40
REV. 02, 15 JUN 2008 3-15

Volume 8
REV. 02, 15 JUN 2008 3-16

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REVISION NUMBER DATE ENTERED YOUR INITIALS

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Chapter 1 Eddy Current Examination

Section 3 Qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Chapter 3 Personnel Training, Qualification and Certification

REV. 02, 15 JUN 2008 TOC-2

Section 1 General High Frequency Eddy Current (HFEC)

3. This is written to provide Chautauqua Airlines Inspectors with a written procedures

REV. 02, 15 JUN 2008 1-1

REV. 02, 15 JUN 2008 1-2

To gain access to the inspection area due to limited accessibility or

3. Probes may be tested in accordance with the procedure outlined in Section 2.

REV. 02, 15 JUN 2008 1-3

REV. 02, 15 JUN 2008 1-4

H. Equipment Calibration for Inspection of Aluminum Alloy

FREQ 250 kHz

REV. 02, 15 JUN 2008 1-5

1. Calibrate the eddy current instrument as follows:

REV. 02, 15 JUN 2008 1-6

I. Equipment Calibration for Inspection of Titanium Alloy

FREQ 1.0 MHz

REV. 02, 15 JUN 2008 1-7

1. Calibrate the eddy current instrument as follows:

REV. 02, 15 JUN 2008 1-8

J. Equipment Calibration for Inspection of 4130, 4340, 300M Alloy

FREQ 100 kHz

REV. 02, 15 JUN 2008 1-9

1. Calibrate the eddy current instrument as follows:

REV. 02, 15 JUN 2008 1-10

REV. 02, 15 JUN 2008 1-11

REV. 02, 15 JUN 2008 1-12

Inspection for Cracks Propagating from an Edge Cutout

REV. 02, 15 JUN 2008 1-13

REV. 02, 15 JUN 2008 1-14

Inspection for Cracks Propagating from Bearing Holes

4. Inspection for Cracks Propagating from Bearing Holes or Bushing Holes or

REV. 02, 15 JUN 2008 1-15

M. Acceptance or Rejection Criteria

REV. 02, 15 JUN 2008 1-16

Section 2 Eddy Current Process Control