Ultrasonic phased-array and Eddy

current array as approved methods for

aircraft maintenance

Presented by: Andre Lamarre, Olympus NDT

ATA Conference 2006, Fort Worth, Texas

Presentation plan
‹ Eddy current array principles
‹ B737 doubler edge with eddy
current array
‹ Ultrasonic phased-array principles
‹ B737 scribe line with ultrasonic
phased
‹ Proposed method for HF ECA
‹ Remote visual NDI
‹ Bondmaster Arrray

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Maintenance procedures already qualified
‹ Boeing 737 (Service bulletin 737 NDT 53-30-25 part 6, dec 2004)
– Inspection of doubling edge
– Omniscan ECA + ECA array probe

‹ Boeing 737 (Service bulletin 737 NDT 53-30-25 part 6, dec 2004)
– Fuselage skin scribe mark
– Omniscan PA + PA probe

‹ Boeing DC-9 (Service bulletin DC9-32A350, dec 2004)

– Inspection of landing gear
– Omniscan PA + PA probe

‹ Gulfsteam ( 3 Service bulletin already issued)

‹ Airbus (soon…)
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Maintenance procedures in-development
‹ Airbus A330 for corrosion (for Lufthansa)
– Omniscan ECA + ECA probe
‹ Airbus A320 Landing gear
– Omniscan ECA
‹ Airbus A340-500-600
– Wing box
– Omniscan PA
‹ Airbus A380
– Glare inspection
– Omniscan PA

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Omniscan product line:
The Omniscan Family

• Modular/multitechnology unit

• 1 system Æ all techniques (OMNI)

• 6 different modules commercially available:

¾PA (16:128 phased array) + UT (1 channel)
¾PA 32:128
¾ PA 16:16
¾ECA (Eddy current array)

¾Manual UT 16:16 and 16:64 NEW!!!

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What is Eddy Current Array?
‹ Eddy current array technology is the ability to
electronically drive several eddy current sensors
placed side-by-side in the same probe assembly.

‹ Data acquisition is performed by multiplexing the eddy

current sensors in a special pattern that will avoid
mutual inductance between the individual sensors.

‹ Most eddy current probes and techniques for flaw detection

can be used with eddy current array probes.

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Eddy current array description

Single coil: slow n coils: n x faster

‹ Increases the scanning speed.

‹ Covers a larger area in a single probe pass while maintaining
a high resolution.
‹ Reduces the need for complex robotics to move the probe on
the surface; simple manual scan is often enough.
‹ Improves flaw detection and sizing with C-scan imaging.
‹ The probe can be shaped to follow the shape of complex parts
to be inspected

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What Is an EC Array Probe ?
‹ EC array probe composed of many coils
to allow higher sensitivity
‹ Each coil scans a specific area
‹ Each coil is optimized for a specific
application
‹ No crosstalk between coils
‹ Any shape is possible
‹ Need special built-in multiplexing
electronics

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ECA - Probe
‹ Can be optimized for
different applications.
‹ Can be shaped to
follow the part to
inspect.

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ECA – Signal Representation
ECA probe over a flaw Each coil produces an The amplitude of the signal
signal is color-coded into a C-scan view

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Boeing 737 Skin crack detection at doubler edge

‹ Service bulletin 737 NDT 53-30-25 part 6, dec

2004.
‹ Description of the application:
– Shear and compression loading cause cracking at the
doubler edge.
– Cracks need to be detected at their initial stage during the
"C" Check, unless they will grow in length and depth to the
point that, they can be visually seen on the fuselage skin
outer surface.
– If the crack reach the surface, the aircraft must be removed
from service to perform the repair and the cost involved is
enormous.
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Boeing 737 Skin crack detection at doubler edge
‹ The inspection is done from the outside and crack as small as 0.240”
long by 0.010” deep located at the edge of the doubler need to be
detected.
‹ Benefits:
– Simple manual inspection
– C-Scan allows easy location
of the doubler edge for fast
and simple detection of the
initiating cracks
– Better reliability
– Better reproducibility
– Time saving:
» Normal time: 200 hours Inside of
» With ECA: 48 hour the skin
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Boeing 737 Skin crack detection at doubler edge
‹ During acquisition, the user can see very well the doubler edge
represented by the light to dark green color transition.

‹ Fastener will
show up in light
green.
‹ Defect above
the rejection
level are in red
like shown in
this picture
‹ Detect
subsuface crack
at doubler edge,
6mm (0.25”)
long by 0.25mm
(0.010”) deep

‹ . 13
Boeing 737 Skin crack detection at doubler
edge – Available probes
‹ Standard Crack probe – SAB-067-005-032
– Probe coverage of 67 mm (2.64in.) in one pass
– Penetration in aluminium of 1.0mm to 3.5mm
(0.040in. to 0.120in.)
– Detection capability
» Subsurface at crack at doubler edge, 6mm (0.25”) long
by 0.25mm (0.010”) deep
» Second layer crack of 3.8mm (0.150in.) long at fastener.
The first layer can have a thickness up to 2mm
(0.080in.) of aluminium

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Equipment listing
‹ Omniscan ECA: OMNI-ECA4-32
‹ Probe: SAB-067-005-032
‹ Encoder: SXA-270

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Phased-array instrumentation evolution
‹ 1994: Tomoscan FOCUS
– 20kg, requires computer, low
data transfert

‹ 2002: Omnsican PA
– 5 kg, portable, stand-alone,
high data transfert
– Battery operated, modular
– 1/3 selling
– Designed based on users
comments and expectations

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Ultrasonic phased-array description
(linear scan)

Full coverage of the weld with focused beam

Fast electronic scan: up to 20 kHz
Allow to cover the weld in one-line pass

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Ultrasonic phased-array description
(sector scan)

Create different inspection angles with the same probe

Allow the inspection of complex shape components
Full volume coverage with focused beams
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Scribe line background
‹ Flight Standards Information Bulletin for Airworthiness (FSAW 03-10B)
issued on November 2003 titled: Fuselage Skin “Scribe Mark” Damage
on Boeing 737 Aircraft
‹ Reports:
‹ Damage has been reported along fuselage skin lap joints, butt joints,
and other areas of several aircraft caused by the use of sharp tools
used during paint and sealant removal
‹ Use of sharp instruments can result in lines scribed in the fuselage skin
‹ Lines scribed in the pressurized skin, if undetected, can result in
cracks and possibly lead to widespread fatigue damage. l
‹ All commercial aircrafts who went to a repaint and sealant removal
process are susceptible to have scribe marks

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Boeing 737 configuration

Picture of a scribe mark:

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Advantages of phased-array
‹ No paint removal (huge time saving)
‹ Sector scan imaging
‹ Omniscan PA easy to operate
‹ The smallest configuration of the Omniscan
PA 16:16 is enough (economic)

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Search for defect
– 0.200 inches (5.08 mm) long
(or more)
– Are in the forward and aft
direction
– Are 50% of the skin thickness
in skins that are from 0.032 to
0.044 inch (0.81 to 1.10 mm)
thick
– On the outer surface of the
skin and in an area that
begins approximately 0.030
inches (0.76 mm) above the
lower edge of the upper skin
and continues to 0.063 (courtesy of Southwest Airlines)
inches (1.60 mm) below the
lower edge of the upper skin.

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Scribe line inspection
‹ The phased-array probe used
is an off-the-shelf probe,
‹ The frequency of the probe is
10 MHz
‹ Mounted on a wedge
‹ Sector scan range from 60 to Side of the
Wedge
85 SW Probe

‹ No encoder needed angle beam

Part

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Scribe line inspection

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Omniscan PA imaging

Scribe mark indication Fastener hole indication

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Conclusions about scribe mark
‹ Inspection for scribe mark can be done without paint
removal
‹ Omniscan PA referenced in the Boeing NTM manuals, 737
NDT Manual, Part 4, 53-30-06.
‹ Extremely fast payback
‹ Omnsican PA now used by most of the airliners

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Proposed Method of HF inspection

0.06 in to 1 in
to the edge

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Proposed Method of HF inspection
‹ Eddy current array
inspection
‹ 32 coils
‹ No dead zone at the
edge
‹ 27 mm long

Play movie
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Proposed Method of HF inspection
‹ One pass inspection
‹ Notch detection from
0.06 to 1 in to the edge
‹ Reliable inspection
(100% full coverage)
‹ Easy interpretation on
Cscan
‹ No need for encoder

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Other Olympus NDT innovated
products

‹ Visual
assisted NDI inspection
‹ Bond master array

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Visual assisted NDI
‹ The industry has requirements to inspect
difficult-to reach areas
‹ Combinaision of:
– Visual instrument (IPLEX: portable battery
operated RVI)
– NDI instrument (Nortec 500)
– EC probe
– Guide or arms
– Remote control
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RVI Videoscope with Eddy Current Probe
The Olympus NDT team Nortec & NDT Engineering Corp in collaboration
with Olympus Industrial (RVI) working together in the manufacturing of a
scanner gun extension that this will allow the attachment of the videoscope
guide scanner gun over fastener collar for inspection.
Scanner Gun Extender Adaptor

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RVI Videoscope with Eddy Current Probe

Scanner Gun Extender Adaptor

with MiniMite attached.

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RVI Videoscope with Eddy Current Probe
By using the scanner gun with Rotating Surface Scanner Probe we will be
able to scan 360 around the fastener collar and should be able to detect
.060 to .100 long flaws breaking beyond the collar. This will be fast and easy
inspection.

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RVI Videoscope with Eddy Current Probe
Other Olympus NDT assessories for the support of RVI videoscope eddy
current inspection. Nortec remote null and erase.

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Bond Master Array
‹ Pitch /Catch Array
‹ Multiplexer
‹ 13 Pitch / Catch
Probes
‹ Total Coverage : 12
inches in one sweep
‹ Detects .75 in
delamination

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Scan sequence illustrated

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BondMaster array

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 Thank you for your participation

Olympus NDT Workshop on the use of Omniscan MX phased-array for

Boeing 737 aircrafts and other Aerospace NDT applications.
August 15-16, Seattle
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