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NDI Equipment
NDI Equipment
NDI inspection is an inspection technique used to analyze properties of a material, component, system without causing damage. Different terms used to describe this technology.
NDI methods may rely upon the use of electro magnetic radiation, sound and inherent properties of materials to examine. NDI inspection is widely used for examination of composites, Since the attenuation (Scattering and absorption of sound waves) in composites is more less frequency of 5 MHZ or less is used for inspection. For UD plies spaced at 8 plies/mm the frequency used for inspection is about 12 MHZ The frequencies used for NDI inspection is decided based on practice. Most of the NDI techniques short pulses of ultra sound (few micro seconds) are passed into the composite materials from a transmitter end and are reflected back from the surfaces of flaws (defects) and received at the receiver end.
Pulse Echo transducer sends out a pulse of energy, to normal of surface . The pulse is reflected from good matrix reinforcement boundaries, and boundaries associated with flaws, The position of flaw and size of flaw is determined by the total pulse travel time and detected amplitude
Through Transmission
Reflections occur due to the presence of discontinuities and the surfaces of the test article. Reciver being placed on the opposite side of the component and facing the transmission probe. Compared to pulse echo there is no dead zone which means that flaw can be detected at all depth through the thickness of the part.
Inspection Techniques
Visual Inspection Tap test A scan
C scan-Squitter
C- Scan - Bubbler
Infrared
Surface Scratches, Surface Depressions on Bag side and Tool side, Surface Resin Ridges, Tedlar Wrinkles, Bondable Teflon Wrinkles, Missing, ResinRich Areas, Core Edge Depressions, Part War page, Honeycomb Core Node Bond Separation, Radius Bridging, Surface Resin, Foreign Material Detected by NDI, Surface Resin Starvation, Internal voids, Porosity
Thickness variation in parts, delaminations, Disbonds sandwich (Metallic cores),
The major factors deciding selection of NDI inspections are Engineering Drawing/Manufacturing standards Machine parameters and capacities Part sizes Part types Part profile complexities
Class A Visual inspection and instrumental NDI First cure of each production part Visual inspection and instrumental NDI each detail part and bond line after respective cures
Class B Visual inspection and instrumental NDI at designated locations in the Engineering drawing as per Boeing approved plan Class C Visual inspection and instrumental NDI for each production part according to the sampling plan approved by Boeing Class D Visual inspection of the production part
1.
NDI Techniques (In house) and their selection criteriaC SCAN SQUITTER
2. Machine parameters-
Height
Inspection speed Max. linear acceleration No of axes (X,Y,Z,A,B) 3D rotation/Limitation angles Transmission medium (Coupler) Mode of inspection Range of parts can be inspected Complexity Geometries can be inspected
2.5 m
1.67 m/s 1.5 m/s 10 A= +105 to -105 B= +180 to -180 Water Pulse echo and Through transmission Existing inspection- Through transmission Monolithic parts, sandwich parts, metallic (Skins), Ceramic skins e.t.c Flat, Semi curved, C shaped, S shaped, T shaped Part surface
NDI Techniques (In house) and their selection criteria Importance of part bunching in squitter Time study
Case 1 Scanning of single part - FACC part number FK13798 L=1.1M W=0.65M 1. 2. 3. A single part FK 13789 was given to squitter for scanning Machine was ruuned at 60 % of maximum speed. The overall scanning time for the above mentioned part was 51 Minutes.
Reason
Before attaining the maximum acceleration of the machine (Which is supposed to be attained at 6.5 m) the machine is decelerated immediately after scanning the part Width of = 0.65m Since the maximum speed of the machine is not utilized the overall inspection time is more.
NDI Techniques (In house) and their selection criteria Importance of part bunching in squitter Time study
1.
2. 3.
Reason In this case machine was ruuned at 60% of maximum speed Scanning length of the machine was 2.6m (Total width of 4 parts)
The total scanning time for 4 parts was less compared to scanning a single part. This study shows the importance of utilizing the maximum scanning length of the machine
NDI Techniques (In house) and their selection criteria Fixture Study
The present fixture in Water jet using for programs excluding Boeing program is below Usable dimensions Length=6.2 m Width = 2.3 m Figure shows spirit- lower panels of 3 different sizes bunched in the fixture. Presently parts are scanned as per ship set requirement and plan Parts having same ref stds are bunched together. Almost 80 percentage of the fixture length is used in this bunching plan. Suitable orientation of the part in fixture also plays a major role in reducing overall inspection time
Part name
Model
Panel 1 inbd
Panel 3 inbd
1.613X0.764
53
Panel 4 inbd
1.795X0.495
60
Panel 5 inbd
1.77X0.435
57
Panel 6 inbd
1.667X0.415
53
Panel 7 inbd
1.346X0.376
52
Part name
Model
Panel 1 outbd (Monolithic) Panel 1 mid outbd (Monolithic) Panel 3 outbd1 (Monolithic) Blow down Panel 1 Blow down Panel 2 Blow down Panel 3
1.032X0.223
01.825X0.51
53
0.418X0.117
20
24 24 24
NA
NA
Part name
148A7406-7
Model
148A7406-8
60
148A7406-10
60
Limitations- C scan Squitter 1. 2. Parts having different ref stds cannot be bunched and inspected Machines maximum speed cannot be utilized, because the generated graphics will be having discrepancies and distortions 3. 4. Local areas where parts clamped are to be scanned again in A scan machine Inspection of holes less accurate and need to be inspected in A scan Advantages - C-scan Squitter
1. 2. High repetitive accuracy due to stable design. High accessibility due to slim construction of inspection mechanics (e.g., U-shapes, aircraft structural parts and exterior panels). 3. 4. 5. 6. Product-specific inspection area due to modular construction. Corrosion resistance Collision protection Automatic water control - adaptation to inspection head position.
NDI Techniques (In house) and their selection criteria C SCAN BUBBLER
Machine parameters- C-scan Bubbler
No of axes (X,Y,Z) Transmission medium (Coupler) Mode of inspection Range of parts can be inspected Complexity Geometries can be inspected Water Pulse echo and Through transmission Existing inspection- Pulse echo Monolithic parts, sandwich parts, metallic (Skins) Flat, T shaped, C shaped, L shape Part surface
1.0 M
PART 1- Scan 2
PART 2-Scan 3
6.0 M
Part name
Model
STIFFNER-SPAR-HORIZ-UPPERINBD
TEE-SPLICE-UPPER-BUILD DOOR
1.32X0.253
50
5.737X0.331
172
STIFF-SPAR-HORIZ-LWR
5.736X0.326
172
0.587X0.216
42
0.647X0.248
32
Part name
Model
LONGERON INBOARD-LH
SPLICE-WEB-SPAR-FRONT
0.688X0.532
42
Limitations- C scan Bubbler Low inspection speed Two times Inspection of ref. STD irrespective of part (NADCAP) requirement Re inspection of part in A scan for part hole and radius and un identifiable defects Maximum part size which can be inspected in existing fixture is 6.0 MX 1.0M, So part bunching is limited Limitations in scanning sandwich parts Advantages - C-scan Bubbler
Machine can inspect a part of Length 600MM Width 1,000M______thickness ____ MM, With present capacity
General notes