A320 Rod Eye End Magnetic Particle Inspection In … · AIRBUS A320 Rod Eye End Magnetic Particle Inspection In-Service Feedback. The 53. rd. Annual ATA NDT Forum-Albuquerque, New

Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1

AIRBUS A320 Rod Eye End Magnetic Particle Inspection In-Service Feedback

The 53rd Annual ATA NDT Forum-Albuquerque, New Mexico-2010

Presented by

Steven CRUMMACKSENIOR NDT ENGINEER,CUSTOMER SERVICES, AIRBUS.

September 2010

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Content

IntroductionComponent Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion

Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 2

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In-Service Feed BackAIRBUS CUSTOMER SUPPORT

inspection

Introduction

Reject RateProcedure

Tooling


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Content

IntroductionComponent

Elevator Servo Actuator Rod Eye EndIn-service finding Rod Eye End Rupture

Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion


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Component


Part Number 341203-XXX(Cadmium Plated, Stainless Steel 15NCD16)

A320 Elevator Servo Actuator Rod Eye End

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Component

Semptember 2010

A320 Elevator Servo Actuator Rod Eye End

Part Number 341203-300

Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 6

Current Part Numbers 341203-300/400/500

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Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1

Component

Page 7

One case of elevator servo control disconnection experienced on A320 Family.

Rupture occurred at level of servo control rod eye-end .

Operators were informed thru OIT .

In-service finding Rod Eye End Rupture

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Content

IntroductionComponent Thresholds and Interval

AimService Bulletin

ProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion


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Thresholds & Intervals

Semptember 2010

Inspection aim, ensure servo-control disconnection does not occur, before threshold or between Intervals.


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Thresholds & Intervals

SB A320-27A1186Threshold: 5,000 flight cycles.Interval: 5,000 flight cycles.


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Content

IntroductionComponentThresholds and IntervalsProcedure

Method and samplingToolingField StrengthInterpretationDe-Magnetisation

POD (Probability Of Detection)In-Service Customer feedbackConclusion


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Procedure

AOT/SB A320-27A1186 Magnetic Particle Inspection

Workable over range facilities available to our operators.

Sampling completed in maintenance environment.

Verified 5mm(0.196 inch) x 0.5 mm(0.0196 inch) crack detectable.

Sampling confirmed a rejection rate of 15%.


Method and Sampling

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Procedure

Semptember 2010

Stationary bench.Magnetised head stocks. Note: Not current flow.


Tooling

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Procedure

Direct Current avoids field concentration in the Cadmium plating.


Defects originate in the base material.

Tooling

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Procedure

Semptember 2010

Field strength: below saturationIncrease crack resolution Reduce background fluorescence

Magnetic field Indicator shows working value of1990 A/m


Field Strength

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Procedure

Semptember 2010

Misleading artefacts Eliminated under magnification.


Once seen, there is no doubt over a genuine crack.Interpretation

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Procedure

Avoids intensifying artefacts(spurious indications) during Indication confirmation.


Before each magnetisation, de-magnetise.

De-Magnetisation

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Content

Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion


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POD (Probability Of Detection).

Semptember 2010

POD ( 90/95) criteria

90% is the probability of detection,

95% is the level of confidence (confidence interval)

False alarm rate to be considered.


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Content

Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedback

Coil or BenchBackground fluorescenceResidual field Magnetic Yoke

Conclusion


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In-Service Customer feedback

Semptember 2010

Widely available,Variable field strength.

Field strength constantIn area of interest.


Magnetised heads Encircling coil

Coil or Bench?

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Some customers internal standard practices required high sensitivity: Zero crack tolerance.

Background fluorescence was reduced by:Solvent based spray to remove excessive fluorescence. Extension of dwell time to resolve indication.

With effect of:

Background Fluorescence

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Difficult to resolve indications under magnification

Not practical to categorise as cracks or otherwise. Convention states, call indications cracks.

Result, increased sensitivity over and above SB.




Reject rate increased from 15% to 85% not practical.

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In conclusion:Flushing step not sufficiently robust.

No justification to modify the current procedure. As standard method meets SB requirement.




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Suggestion to exploit the residual field, which is closeto the required field strength?

Variable in-service = no guarantee of sensitivity.

Residual field

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Issues:Majority of yokes only work in AC.DC option not readily available. Achieving uniform and sufficient Field Strength challenging.

Conclusion: not able to recommend Magneticyokes


Use of Magnetic yokes?

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Content

Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion


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Conclusion

Key parameter detectable defect size .

Detectable Defect size determines threshold and interval.

Airbus procedures aim to be “fit for purpose”.

Increase sensitivity = raises reject rate.


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Conclusion

Operator Feedback:

Valued and productive.Positive effect on future procedures.


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Conclusion

Thank you for your FEEDBACK

Please continue.


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Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1

© AIRBUS S.A.S. All rights reserved. Confidential andproprietary document.

This document and all information contained herein is the soleproperty of AIRBUS S.A.S.. No intellectual property rights aregranted by the delivery of this document or the disclosure ofits content. This document shall not be reproduced ordisclosed to a third party without the express written consentof AIRBUS S.A.S. This document and its content shall not beused for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. Theyare based on the mentioned assumptions and are expressedin good faith. Where the supporting grounds for thesestatements are not shown, AIRBUS S.A.S. will be pleased toexplain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321,A330, A340, A350, A380, A400M are registered trademarks.

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A320 Rod Eye End Magnetic Particle Inspection In … · AIRBUS A320 Rod Eye End Magnetic Particle Inspection In-Service Feedback. The 53. rd. Annual ATA NDT Forum-Albuquerque, New

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