NON-DESTRUCTIVE TESTING 6.18.3.2 EDDY CURRENT METHODS · Date 2 nd Issue : 07 March 2011 CAAP Approved Maintenance Organization No. 01-76 Rev. NON-DESTRUCTIVE TESTING 6.18.3.2 EDDY

Date 2nd Issue : 07 March 2011 CAAP Approved Maintenance Organization No. 01-76

NON-DESTRUCTIVE TESTING

6.18.3.2 EDDY CURRENT METHODS

3.3 Differential Coil System. Figure 5 shows a coil arrangement which is also

a comparison method, but in this case adjacent portions of the test specimen are compared with each other. The coil windings are, in effect, identical to the comparative coil system shown in Figure 4.

Figure 4 COMPARATIVE COIL SYSTEM S

Figure 5 DIFFERENTIAL COIL SYSTEM S

SECTION NO. 6.18.3.2 Rev. No.

0

Rev. Date

March 2011

Page No.

7/21

Chapter

6




3.4 Surface Coils. In aircraft work a single coil is generally used, with the axis of the coil normal to the surface being tested (Figure 6). A ferrite core is used to increase sensitivity to small defects, and the arrangement is used for detecting cracks in flat surfaces, curved surfaces or holes, by mounting the coil within a specially shaped probe. Impedance changes obtained during a test are compared with those obtained from a defective part or a reference piece.

Figure 6 SURFACE COIL


0

Rev. Date

March 2011

Page No.

8/21

Chapter

6




4 TYPES OF CIRCUITS

4.1 Bridge Circuits. Figure 7 shows a bridge circuit, one arm of which consists of two adjustable controls and a coil, and the other arm comprises the reference and test coils. The bridge is balanced initially (meter zeroed by adjustment of the variable resistor and inductor) with the probe located on a flawless specimen. In use, any alteration in the impedance of the probe coil (due to faults in the test piece, or to lift-off) will unbalance the bridge and result in a deflection of the meter needle.

4.2 Resonant Circuits. The capacitance of a coil is usually small in relation to its inductance. However, if a capacitor is connected in the same circuit as a coil, since inductive reactance increases with frequency and capacitive reactance decreases with frequency, a condition will occur, at some frequency, when the effects are equal and opposite. This condition is known as resonance and the circuit then behaves as if it contained only resistance, resulting in a large change in current flow.

Figure 7 BRIDGE CIRCUIT


0

Rev. Date

March 2011

Page No.

9/21

Chapter

6




4.2.1 Figure 8 shows a typical eddy current circuit which operates on the resonance principle. The probe is a parallel tuned circuit connected to the grid of an oscillator and determines the frequency at which the circuit oscillates. If the flux density (and hence the impedance) of the probe coil is altered (e.g. by placing the probe on a metallic object) the oscillator frequency changes. Consequently, the frequency developed in the anode tuned circuit is no longer the frequency at which that circuit is tuned. This results in a change of impedance, which is recorded on the meter through the secondary windings of the anode coil.

4.2.2 Operation of the circuit shown in Figure 8 is dependent upon

adjustment of the controls to suppress lift-off. With the probe located on the test specimen the anode circuit is tuned to a frequency in sympathy with the probe circuit by adjustment of the variable capacitor (i.e. the lift-off control) until the meter reads zero. If the probe is now removed from the specimen a change in impedance will again occur and result in deflection of the meter needle; this deflection can be counteracted by adjustment of the set-zero and lift-off controls. Further adjustment of these two controls will enable a zero meter reading to be obtained with the probe on or off the specimen. Any change in the specimen (e.g. a defect) will result in a change in the impedance of the probe coil and a deflection of the meter needle, regardless of the presence of, for example, a paint film of uneven thickness.

A different type of resonant circuit is shown in Figure 9, the probe coil and capacitor in this case being connected in series. Lift-off is suppressed by the addition of a compensating voltage to the measurement voltage.


0

Rev. Date

March 2011

Page No.

10/21

Chapter

6




5.1 PHASE ANALYSIS Where one of the parameters affecting impedance is required and all others can be assumed to be constant, the measurement of total impedance changes will satisfactorily reveal the presence of a defect or change in the unknown parameter, provided that a suitable reference piece is used for comparison. However, in many cases it is necessary to separate the reactive and resistive components of impedance in order to detect a particular type of defect and more sophisticated equipment becomes necessary.

Figure 10 shows the oscilloscope trace of a signal containing two voltages, V1 and V2,

which are representative of the signal which could be obtained from eddy current equip-ment under certain test conditions. While the voltages are of the same frequency they can be seen to start at different points of the time scale, the difference resulting from the effects of reactance and being known as a phase change. Eddy current testing based on the use of phase change is known as phase analysis.

Figure 9 SERIES RESONANT CIRCUIT


0

Rev. Date

March 2011

Page No.

11/21

Chapter

6




5.2 One method of suppressing the unwanted components of the measurement voltage (i.e. probe coil voltage) and presenting only the parameter required, is to include a phase sensing device in the circuit. This operates on the principle that only those components which are in phase with a reference voltage are passed to the meter. Figure 11 shows a typical phase sensing circuit in which the measurement voltage is applied to one diagonal of a bridge and a reference voltage to the other. The rectifiers act as switches which pass current during one half of each cycle of the reference voltage only, but no reference current flows through the meter due to the symmetry of the bridge circuit. The measurement voltage is applied to the meter during those periods when the rectifiers are conducting, and, by varying the phase of the reference voltage, unwanted components of the measurement voltage can be eliminated.

Figure 10 PHASE DIFFERENCE


0

Rev. Date

March 2011

Page No.

12/21

Chapter

6



6.18.3.2 EDDY CURRENT METHODS 5.3 The resistive and reactive components of the measurement voltage (Vi and V.

respectively) can also be separated, fed to separate plates of a cathode ray tube (CRT) and presented as a two-dimensional disp lay on the screen. By suitable phase controls the vertical and horizontal components can be made to represent, for example, conductivity variations and dimensional variations respectively. The most common types of display are the vector point, ellipse and linear time base.

5.3.1 Vector Point. A spot is projected

on to the screen of the CRT, representing the end of the impedance vector (Z) (Figure 12) and is adjusted to the centre of the screen when the test piece has the same properties as the reference specimen. Any anomaly in the test piece t: will result in movement of the spot, the direction of movement being an indication of the cause of the anomaly. If more than one variable is present, since the position of the spot indicates direction and magnitude, the cause can often be determined by vector analysis.

Figure 12 VECTOR POINT

Figure 11 SENSING CIRCUIT


0

Rev. Date

March 2011

Page No.

13/21

Chapter

6




5.3.2 Ellipse Method. A comparative coil arrangement is also used in this method.

In the balanced condition a horizontal line is shown on the screen of the CRT whilst an unbalanced condition can be shown in either of two ways. One variable can be displayed by a change in the angle of the line and a second variable by the formation of an ellipse (Figure 13). By analyzing the position and shape of the ellipse both variables can be evaluated.

5.3.3 Linear Time Base. A spot moving across the screen at a constant rate can be

adjusted to show the wave-form of the voltage from a comparative coil system. A change in impedance will alter the wave-form and either of the components of impedance can be measured by adjustment of the phase shift controls. To assist in measuring any changes, the screen is often fitted with a slotted cursor (Figure 14).

Figure 14 LINEAR TIME

Figure 13 ELLIPSE METHOD


0

Rev. Date

March 2011

Page No.

14/21

Chapter

6


Figure 15 SURFACE PROBES



6 PROBES Unlike ultrasonic probes, the probes used in eddy current testing, because they are connected to the material by a magnetic field, do not require a coupling fluid, and no surface preparation is necessary other than the removal of any surface condition which would hinder free movement of the probe. Coils are also normally wound on a ferrite core, and this has the effect of concentrating the magnetic field and increasing sensitivity to small defects. Coils are often protected by enclosures in a plastics case, but the ferrite core is often left unprotected when required by particular test conditions. To maintain the coils in close proximity to the work it is often necessary to design a probe for one particular use only; some of the probes commonly used in aircraft work are discussed in 6.1,6.2, and 6.3.

6.1 Surface Probes. Figure 15 shows two typical surface probes. (A) could be used for detecting surface cracks, and would be connected to a resonant circuit type of test set, whereas (B) could be used for coating thickness measurement or conductivity tests and would be connected in a bridge circuit type of test set. In the case of (A) a simple jig may be necessary to prevent spurious indications due to inadvertent probe angulations.


0

Rev. Date

March 2011

Page No.

15/21

Chapter

6




6.2 Hole Probes. Hole probes used during material manufacture would normally con-

sist of a coil, the axis of which would be coincident with the axis of the tube under test, but in aircraft work a hole probe is normally located with the coil diametrically across the hole to achieve greater sensitivity. This type of probe is therefore a surface probe used for testing the surface of a hole. Figure 16 shows a typical hole probe of the latter type, the main use for which would be the detection of radial cracks round fastener holes.

6.2.1 The actual position of a crack can be determined by using an offset coil as illus-

trated, or by shielding one end of the coil.

6.3 Special Probes. Probes may be designed to suit any application, the object being to present a coil at a particular position on a component, so that information can be obtained from changes in the coil's impedance. Examples of the use of special probes would be for the detection of cracks in wheel bead seats, turbine engine compressor or turbine blades, and each of these probes could be connected to a single test set of suitable frequency and complexity. Probes are also designed with a view to eliminating the need for disassembly when carrying out routine maintenance operations.

Figure 16 HOLE PROBE


0

Rev. Date

March 2011

Page No.

16/21

Chapter

6




7 REFERENCE PIECES +- In order to calibrate the equipment, standard reference pieces, manufactured from a

material similar to that being tested, are necessary. These pieces should contain defects of known size and shape, so that the change in coil impedance against a known defect could be used as an acceptance limit.

7.1 A typical reference piece for surface crack tests would contain, for example, three

cuts of different depths, the depth being marked adjacent to each cut, and the block being marked with the material specification. The test acceptance level could then be related to a signal of the same amplitude as that obtained on a specified cut in the block.

7.2 Reference pieces are usually small in size and can be taken to the test location so

that quick cross-reference can be made between the reference piece and the test specimen.

NOTE: Since the manufacture of a reference piece involves the removal of metal (by

saw cut or spark erosion), the phase and magnitude of the impedance changes will not be identical with those obtained from a natural crack of similar depth. For this reason, actual defective aircraft components are some-times used to give comparative readings.

8 TYPICAL APPLICATIONS OF EDDY CURRENTS. The eddy current equipment

used in many material manufacturing processes is very sophisticated and completely automatic. Bar, tube and wire materials are normally passed through encircling coils of suitable size, and defects are both displayed on a cathode ray tube and recorded by tape or memory store. Audible warning, marking, and defective component rejection systems, actuated by the defect signal, are also often included. A recent innovation is the use of rotating probes through which bar material can be passed, the advantage of this method being an increase in the sensitivity to surface cracks. In aircraft maintenance work, however, eddy current equipment is usually restricted to conductivity tests and crack detection, mainly by the use of surface probes. Sophisticated equipment such as that described above is not normally required and equipment is usually portable and battery operated. The following paragraphs describe typical eddy current applications.


0

Rev. Date

March 2011

Page No.

17/21

Chapter

6




8.1 Checking Fastener Holes for Cracks. Suitable equipment for testing holes would be a simple impedance test set (i.e. not including phase analyzing circuits) with lift-off control, and the probe would be similar to that shown in Figure 16, adjusted to be a snug fit in the hole. The reference piece should be of similar material to that being tested, and should contain holes of the same size as the probe with natural cracks or artificial notches at various depths in the hole to simulate cracks of maximum acceptable size.

8.1.1 The following procedure should be used when carrying out a test:

(i) Clean loose paint, dirt, burrs, etc. from inside and around the holes being checked.

(ii) Calibrate instrument and adjust for lift-off in accordance with the manufacturer’s

instructions.

(iii) Insert probe in hole in reference piece and adjust depth stop to obtain maximum needle deflection from a selected notch or crack. Adjust sensitivity to give the specified scale deflection from the crack.

(iv) Insert probe in hole in test specimen and slowly rotate, noting and marking

any holes producing needle deflections greater than that from the reference piece. Re-check probe in reference piece frequently.

NOTE: Any ovality in hole diameter will give a meter deflection which can be

confused with the signal from a crack. Generally the indication from ovality shows a much slower change than that from a crack as the probe is rotated.

(v) Repeat (iii) and (iv) at incremental depths to cover the hole surface

completely.

(vi) Ream out marked holes as recommended by aircraft manufacturer and repeat test with an appropriate sized probe and reference piece hole.


0

Rev. Date

March 2011

Page No.

18/21

Chapter

6




8.2 Checking Heat Damaged Skin. The conductivity of aluminum alloy sheet will

increase with exposure to elevated temperatures up to approximately 500°C, and above this temperature obvious signs of damage such as melted or charred metal become apparent. Tests conducted on the surrounding material will show the extent of the area in which the metal is below strength requirements and must be replaced.

8.2.1 The acceptable range of conductivity readings depends on the type of material

and its heat treatment condition, and these readings may be stipulated in the appropriate Maintenance Manual. As a rough guide, the conductivity of unclad 7075- T6 material is 31 to 35% IACS, but the important reading in relation to heat damage is the change in conductivity between sound and defective material.

8.2.2 A conductivity meter should be used for this test, and this will normally be an

impedance change instrument, with a meter and separate scale graduated in percentage IACS. This equipment is supplied with a surface probe and two test samples, one of high purity copper (with high conductivity) and the other a material of low conductivity, for calibration purposes.

8.2.3 The following procedure should be followed when carrying out the test:

(i) Thoroughly clean area to be inspected.

(ii) Calibrate instrument in accordance with the manufacturer's instructions.

(iii) Place probe on sound skin of similar material and thickness and remote from the heat affected zone, and adjust scale until meter is zeroed. Compare this reading with the expected conductivity.

(iv) Check conductivity all round the affected area, noting any meter deflection,

and marking the skin accordingly. By this means a demarcation line can be drawn round the damaged area, and material removed up to this line.


0

Rev. Date

March 2011

Page No.

19/21

Chapter

6




8.3 Detection of Corrosion. Corrosion on hidden surfaces can be detected by eddy current methods using phase sensitive equipment. If a reading at the normal thickness of a sheet material can be taken, since corrosion reduces the thickness of a sheet, when the probe is over a corroded area a different reading will be obtained. The equipment can be set up by noting the readings obtained from a sound material of, say, 90% of the thickness of the test specimen, and a rough estimation of the volume of corrosion beneath the probe can be obtained during a test.

8.3.1 Equipment is available which is specially designed for thickness

measurement having a meter graduated in appropriate units, but any equipment operating at a frequency which would give a penetration depth at least equal to the sheet thickness could be used to give an indication of the presence of corrosion. Equipment designed for detecting surface cracks and operating at very high frequency would be unsuitable.

8.3.2 Care is necessary when checking for corrosion to ensure that underlying

structure (stringers, frames, etc.), chemically contoured areas, and loose debris, do not cause misinterpretation of results.

8.4 Material Sorting. Provided that a known sample is availab le, eddy current equip-

ment can be used to ensure that a batch of materials is correctly identified, or that a component is made from the correct material. Simple impedance equipment could be used for coarse sorting, but in order to differentiate between materials c losely related in composition, equipment with phase sensing circuits is necessary. By placing the known sample in an encircling coil the characteristic trace of that material can be displayed on an oscilloscope and unknown samples accepted or rejected by comparison.

8.5 Coating Thickness Measurement. The thickness of conducting or non-conducting

coatings on ferrous or non-ferrous bases can be measured using basic eddy current methods; although measurement becomes difficult where the conductivity of the coating and base metal are similar. It is possible to utilize crack detection equipment for measuring thick coatings, by comparing the readings obtained from the test specimen with the lift-off effect obtained when the probe is placed on slips of non-conducting material (e.g. mica) of known thickness.


0

Rev. Date

March 2011

Page No.

20/21

Chapter

6



6.18.3.3 FLUORESCENT PENETRANT PROCESSES

When measuring very thin coatings however (i.e. less than 0·12 mm (0·005 inch», it is recommended that equipment designed specially for coating thickness

1. INTRODUCTION. This leaflet gives guidance on the fluorescent penetrant processes

used for the detection of defects in a component, such as cracks, cold shuts, folds, laps and porosity when these break the surface of the component.

1.1 Fluorescent penetrant processes are used main ly for the detection of flaws in non-

ferrous and non-magnetic ferrous alloys but may also be used for ferrous parts where magnetic flaw detection techniques are not specified or are not possible. In some instances both fluorescent penetrant and magnetic flaw detection techniques may be specified for a particular part (see paragraph 1.5.4). Fluorescent penetrants may also be used on some non-metallic materials, such as plastics and ceramics, but in each case a suitable process for the particular material must be selected. The processes are not suitable for use on absorbent materials.

1.2 Although the processes are usually marketed under brand names, those used on

aircraft parts for which a penetrant process of flaw detection is a mandatory requirement must comply with the requirements of Process Specification DTD 929. It must be ensured that any storage limiting period prescribed by the manufacturer of the process is not exceeded.

1.3 There are two types of fluorescent penetrants, a minor water-based group and a

major oil-based group; the manufacturers of the processes usually specify the materials for which each process is suitable. There are variations in the processes which must be taken into account. For example, some types of penetrants contain an emulsifier, whilst in other processes the penetrant and the emulsifier are applied as separate stages. Again in some processes the use of a dry developer is recommended whilst in others a wet developer is used. The manufacturer's recommendations and instructions for each individual process must be followed carefully to ensure satisfactory results.

NOTE: An emulsif ier is a blending of wetting agents and detergents which enables

excess penetrant to be removed with water.


0

Rev. Date

March 2011

Page No.

1/9

Chapter

6




1.4 Fluorescent penetrant testing is based on the principle that when ultra-violet radiation falls on certain chemical compounds (in this case the penetrant) it is absorbed and its energy is re-emitted as visible light (i.e. the wavelength of the light is changed). Thus, if a suitable chemical is allowed to penetrate into surface cavities, the places where it is trapped and has been drawn to the surface by the developer will be revealed by brilliant greenish-yellow lines or patches (according to the nature of the defect) under the rays of an ultra-violet lamp.

1.5 The selection of the most suitable type of penetrant process (e.g. penetrant dye

(Leaflet BLJ8-2) or fluorescent penetrant; with or without post-emulsification) for any given application must largely be governed by experience, since when correctly used a high degree of efficiency can be obtained with any of the processes. Guidance on some of the factors which should be given consideration is provided in the following paragraphs.

1.5.1 Within a given type of process, the post-emulsification method is generally con-

sidered to be the most sensitive and is usually selected for finished machined parts and for the detection of "tight" defects. However, its use on rougher surfaces (e.g. castings) may be less effective than would be the use of a penetrant containing an emulsifier, since it may pick up the surface texture of the material, thus rendering the detection of actual defects more difficult.

1.5.2 Where large, heavy parts are concerned, and particularly where mechanical

handling is involved, the use of penetrant dyes may be more practicable than that of fluorescent penetrants, since the necessity of darkening a relatively large area before the examination can be made does not arise.

1.5.3 When making "in situ" checks on aircraft, the use of penetrant dyes may be

more suitable where there is sufficient light but in the darker areas a fluorescent process may provide better definition of defects.

1.5.4 With steel castings, for example, porosity may be detected more readily by a

penetrant process than by the magnetic flaw detection techniques (Leaflet BLj8-S) and for this reason the use of both processes is sometimes specified. If the magnetic flaw detection test precedes the penetrant test, great care will be necessary with the intervening degreasing process to ensure that all traces of the magnetic testing medium are removed; otherwise the subsequent penetrant test may be unsuccessful.


0

Rev. Date

March 2011

Page No.

2/9

Chapter

6



6.18.3.3 FLUORESCENT PENETRANT PROCESSES 1.6 Some of the materials associated with penetrant testing have low flash points and

the appropriate fire precautions should be taken. 1.7 Guidance on dye penetrant processes is given in Leaf let BL/8-2. Information on

the performance testing of penetrant testing materials is given in Leaflet BL/l0-9.

2 SURFACE PREPARATION. The major reason for the failure of penetrant processes to provide indications of defects is incorrect or inadequate surface cleaning. For example, embedded extraneous matter can seal off cracks, etc., whilst contaminants remaining on the surface can trap the penetrant and give rise to false indications or, more detrimentally, obscure genuine defects. Thus the surface to be tested must be free from oil, grease, paint, rust, scale, welding flux, carbon deposits, etc., and the method of cleaning selected must be capable of removing extraneous matter from within the defects as well as from the surface to permit the maximum penetration.

2.1 With unmachined steel stampings and forgings it may be necessary to remove rust

or scale by sandblasting. Aluminum alloy forgings may also need light sandblasting. However, the use of such processes must be given careful consideration, since they may result in the filling or "peening-over" of defects. Generally, unless specified otherwise, aluminum alloy forgings should be prepared by a suitable pickling process (e.g. by one of the methods prescribed in Process Specification DTD 901).

2.2 Magnesium alloy castings should be tested after chromating in order to reduce the

risk of corrosion, but the requirements of Process Specification DTD 911, with regard to surface protection, must be taken into account and a suitable sequence devised.

2.3 Where contamination is main ly of an organic nature, degreasing by the trichloro-

ethylene process (unless there are instructions to the contrary) is usually su itable. However, not all types of trichloroethylene are suitable for use with titanium alloys and further guidance on this and other aspects of trichloroethylene cleaning is given in Leaflet BLf6-8. The cleaning of titanium alloys by methanol should be avoided.


0

Rev. Date

March 2011

Page No.

3/9

Chapter

6



6.18.3.3 FLUORESCENT PENETRANT PROCESSES 2.4 Where parts have to be tested "in situ", the use of volatile solvents (e.g. carbon

tetrachloride) as cleaning agents should be given consideration. Where paint is present this should be removed from the surface to be tested prior to cleaning. Subsequent to the test, the surface should be reprotected in the prescribed manner.

NOTE: Suitable fire precautions must be taken where flammable materials are used.

2.5 Sufficient time should be allowed after cleaning for drying-out, otherwise the efficiency of the penetrant may be affected. The time interval allowed for the evaporation of solvents can only be determined by the prevailing conditions of temperature and humidity and the type of solvent used.

3 APPLICATION OF THE PENETRANT PROCESS (WITHOUT POST EMULSIFICATION)

3.1 Application of Penetrant. The penetrant can be applied to the surface by dipping, spraying or brushing; the method used depending largely on the size, shape, and quantity of the parts to be examined. The surface must be dry before the penetrant is applied. Even the condensation which forms on a cold surface in humid conditions may interfere with penetration; in such conditions the part should be warmed, preferably within the temperature range of 70oF. to 90oF.

3.1.1 Dipping Method. Dipping should generally be used where large numbers of

small parts are to be examined. The parts must be completely dried before immersion, since apart from affecting penetration, water or solvents will contaminate the penetrant.

(i) During dipping care must be taken to ensure that the parts are so racked that

air pockets are avoided and all surfaces to be examined are completely wetted by the penetrant.

(ii) The parts should be dipped for a few seconds and allowed to drain, care being

taken to ensure that the solution is able to drain away from any pockets or cavities in the parts. If there is a tendency for the penetrant to dry on the surfaces the parts should be redipped.


0

Rev. Date

March 2011

Page No.

4/9

Chapter

6



6.18.3.3 FLUORESCENT PENETRANT PROCESSES 3.1.2 Flooding Method. The flooding method should generally be used where large

areas are to be examined. The penetrant should be applied with low-pressure spray equipment which will not permit atomization of the fluid, care being taken to ensure that the penetrant completely covers the surface and remains wet. On no account should the penetrant be allowed to dry during the penetration period (paragraph 3.2).

3.1.3 Aerosol Method. Penetrant contained in aerosol-type cans is often used for "in

situ" inspections. The best results are obtained when the can is held about 12 in. from the surface under test.

3.1.4 Brushing Method. The brushing method is generally used for individual items

and items of complicated shape. A soft clean bristle brush should be used and retained only for this purpose. On no account should the penetrant be allowed to dry during the penetration period.

3.2 Penetration Time. The penetration time is the time which has to be allowed for

the penetrant to enter effectively into defects and usually a period of up to ten minutes is sufficient for the larger type defects, but longer times may be necessary where minute defects are being sought. (See Table 1)

3.2.1 Typical penetration times are given in Table 1 but these may vary according to

the temperature and process used. The manufacturer's recommendations must always be followed where these differ from the figures given.

3.2.2 Where the effectiveness of the pre-cleaning process cannot be guaranteed or

where parts have been sandblasted, the penetration time should be extended but it should be borne in mind that this is no guarantee that defects will, in fact, be revealed in such conditions.


0

Rev. Date

March 2011

Page No.

5/9

Chapter

6




TABLE 1

Material Nature of Defect Penetration

Time (Minutes)

Sheets and Extrusions

Heat treatment cracks, grinding cracks and fatigue cracks.

15

Forgings Laps, Cracks. 30

Castings (i) Shrinkage, cracks and porosity. (ii) Cold Shuts.

3-10

20 Welds (i) Cracks, porosity. 20

(ii) Included flux. 1 Plastics Cracks, crazing. 1-5

3.3 Removal of Excess Penetrant. Excess penetrant should be removed by spraying

with running water at a mains pressure of about 30 lb. sq. in. or by the use of an air/ water gun. In the case of self-emulsifying penetrants, it may be necessary with some surfaces to use a detergent solution, supplied by the manufacturer, prior to spraying the developer. It is most important to ensure that the rinsing operation is completely effective, otherwise traces of the residual penetrant may remain on the surface and interfere with the subsequent diagnosis of defects.

3.3.1 After rinsing, the surfaces of the component should be quickly inspected by

means of ultra-violet light to ascertain the efficiency of the rinse. If any general fluorescence is still evident the rinsing operation should be repeated.

3.3.2 If a wet developer is to be used, the surfaces need not be dried but drying is

essential if a dry developer is to be used. On large parts the excess water can be blown off with clean, dry, oil-free air but when parts are of convenient size, drying in a recirculation hot-air drier is recommended. Excessive time in the drier should be avoided, as the penetrant will slowly evaporate.

3.4 Application of the Developer. The developer usually consists of a very fine white

powder which may be applied in (a) the form of a spray, the powder being suspended in a volatile liquid carrier, (b) as a dip with the powder suspended in water or (c) as a dry powder which may be blown on to the component or into which the component may be dipped. The action of the absorbent powder is to


0

Rev. Date

March 2011

Page No.

6/9

Chapter

6



6.18.3.3 FLUORESCENT PENETRANT PROCESSES draw out the dye from the surface defects, thus indicating their position by the

resultant yellowish-green stain when viewed under ultra-violet light.

3.4.1 Where it is suspected that microscopic defects may be present, great care is necessary to ensure that the developer is applied evenly and very thinly, since a thick layer might completely conceal a defect holding only a minute quantity of dye.

3.4.2 Where a wet developer is concerned, the best results are obtained when the

developer is applied by means of a paint-type spray gun operating at an air pressure not in excess of 15 lb. sq. in. The pressure pot of the gun should be equipped with a stirrer to keep the developer agitated and the absorbent particles in suspension. Before pouring the developer into the spray-gun it should be well shaken to ensure thorough distribution of the absorbent particles.

3.4.3 When requirements are not too exacting, small parts can be dipped into a bath

of developer but the action must be performed rapidly to minimize the possibility of the penetrant being washed out of shallow defects. The bath should be agitated from time to time to ensure that the absorbent particles are kept in uniform suspension in the solvent. The formation of pools of developer on the parts during draining must be avoided; otherwise the resultant thick coatings may mask defects.

3.4.4 Due to the usually uneven results obtained, the use of a brush for applying the

developer is not recommended. 3.4.5 After the developer has been applied, the parts should be allowed to stand for

at least 15 minutes and should then be examined in a darkened room, using ultraviolet light. Where doubt exists as to the validity of an indication, the part should be left for at least two hours and then re-examined. If viewing periods are to exceed 30 minutes, the use of special viewing goggles is recommended to reduce the risk of eyestrain and headaches.

NOTE: Portable lamps specially manufactured for fluorescent viewing are

availab le.


0

Rev. Date

March 2011

Page No.

7/9

Chapter

6




4. APPLICATION OF THE PENETRANT PROCESS (WITH POST EMULSIFICATION) In principle the process is similar to that described in the previous paragraph, except for the addition of the emulsif ication step. However, the separate application of penetrant and emulsifier does introduce additional factors which must be taken into account and these are described below.

4.1 After the parts have been dipped in the penetrant, the drain-off period should not

be less than 15 minutes and not more than 2 hours. If the period is less than 15 minutes, dilution of the emulsifier by the penetrant may occur and penetration of contaminated defects may not be complete. If the period exceeds 2 hours, partial drying of the penetrant may occur, resulting in exceptionally long emulsif ication times. Once an optimum draining period has been determined for a particular part, it should be adhered to within ±20 per cent, since this period directly influences the process and effects of emulsif ication.

4.2 The parts should be dipped into the emulsif ier (the length of time the emulsifier is

allowed on the parts being somewhat critical), and should be held to the minimum time necessary to give a good water wash, since this will result in the highest sensitivity. It should be determined by experience for each type of part and finish and then strictly adhered to.

4.3 An average emulsification time is about 2 minutes, but may vary between 30

seconds to 5 minutes, according to the surface condition of the part. 4.4 After removal of the emulsifier, the part should be dried, treated in the dry

developer and then inspected for defects. 5. INTERPRETATION OF INDICATIONS. If defects are present and all stages of the

process have been applied correctly, they will be indicated by brilliant greenish-yellow marks on the surface of the part; some may appear immediately as the developer dries but others may take longer to develop. The characteristics of the markings, such as the rapidity with which they develop and their final shape and size, provide an indication as to the nature of the defect revealed (see Figure 1).

5.1 The rate of staining is an indication of the width and depth of the defect, whilst the

extent of staining is an indication of its volume. A wide shallow defect is revealed almost instantly but narrow deep defects may take some time to display the final pattern.


0

Rev. Date

March 2011

Page No.

8/9

Chapter

6




5.2 Scattered dots indicate fine porosity or pitting (Figure 1 (d)), whilst gross porosity

may result in an entire area becoming stained. 5.3 Closely spaced dots, in a line or curved pattern (Figure 1 (c», usually indicate tight

cracks or laps but such patterns are also characteristic of very wide defects from out of which most of the penetrant has been washed. Wide cracks, lack of fusion in welded parts and other similar defects are indicated by continuous lines as shown in Figures 1 (a) and 1 (b).

5.4 All defects should be suitably marked prior to removal of the developer, but crayons

should not be used on highly-stressed components subject to heat treatment, since this is known to induce fractures.

6. REMOVAL OF DEVELOPER. Developer should be removed by washing with water

spray or by dipping the component in an aqueous solution of 2 per cent chromic acid. Since the surface is then in a condition susceptible to corrosion (where this is applicab le) the prescribed protective treatment should be applied without delay.

Figure 1 INDICATION GIVEN BY DEFEC TS


0

Rev. Date

March 2011

Page No.

9/9

Chapter

6


NON-DESTRUCTIVE EXAMINATION

6.18.3.4 MAGNETIC PARTICLE INSPECTION 1. INTRODUCTION. This Leaflet gives guidance on the detection of surface and sub-

surface defects in ferro-magnetic materials by magnetic processes. The procedures recommended in this Leaflet are complementary to British Standard (BS) M35, and should not be taken as overriding the techniques of examination prescribed by the manufacturer of a particular component, either in drawings or in approved manuals.

1.1 Magnetic flaw detection tests are applied to many steel parts at the manufacturing,

fabrication and final inspection stages. The process is normally applied to all Class 1 aircraft parts manufactured from Ferro-magnetic materials, and to any other parts where the designer or inspection authority considers it to be necessary.

NOTE: A Class 1 part is defined as a part, the failure of which, in flight or ground maneuvers, would be likely to cause catastrophic structural collapse, loss of control, power unit failure, injury to occupants, unintentional operation of, or inability to operate, essential services or equipment.

1.2 The methods of magnetizing in general use are the magnetic flow and the current

flow processes, which are described in paragraph 3. By choosing the most suitable process, or combination of processes, for a particular component, both surface and subcutaneous defects may be revealed.

1.3 Great care must be taken when establish ing a technique of examination suitable for

a particular component, in order to ensure that consistent results are obtained. Operators of magnetic flaw detection equipment should be thoroughly trained in its use, and experienced in interpreting technique requirements and the indications obtained from a test.

2. THE PRINCIPLE OF MAGNETIC FLAW DETECTION. If a component is subjected to

a magnetic flux, any discontinuity in the material will d istort the magnetic field and cause local leakage fields at the surface. Particles of magnetic material applied to the surface of the magnetized component will be attracted to the flux leakage areas and reveal the presence of the discontinuity.

2.1 The sensitivity of magnetic flaw detection depends largely on the orientation of the

defect in relation to the magnetic flux, and is highest when the defect is at 90° to the flux path. Sensitivity is considerably reduced when the .angle between the


0

Rev. Date

March 2011

Page No.

1/17

Chapter

6


NON-DESTRUCTIVE EXAMINATION 6.18.3.4 MAGNETIC PARTICLE INSPECTION

defect and the flux path is less than 45°, so that two tests are normally required with each component, the flux path in the first test being at 90° to the flux path in the second test. Components of complex shape may require tests in several different directions.

2.2 A component may be magnetized either by passing a current through it, or by

placing it in the magnetic circuit of a permanent magnet or electromagnet. The required strength of the applied magnetic field varies considerably, and depends largely on the size and shape of the component and on the magnetic characteristics of the material from which it is made.

2.3 The magnetic particles used to reveal defects are either in the form of a dry

powder, or suspended in a suitable liquid. They may be applied by spray, pouring, or immersion, depending on the type of component. Magnetic flaw detection 'inks' complying with BS 4069 are used in aircraft work, and consist of finely divided black or red magnetic oxides of low coercivity (i.e. they will not retain the magnetism induced during testing), suspended in a liquid (normally kerosene). Pigments may be added to provide a contrast with the surface of the specimen. Black inks are suitable for use on bright, machined components, but red inks may be more suitable for unmachined parts or, alternatively, a thin coat of white paint or strippable lacquer may be added to the component before carrying out the test.

2.3.1 If magnetic inks are left standing for long periods the solid particles settle at the

bottom of the container and form sediment which may be difficult to redisperse. If the machine does not have pump agitation, frequent manual agitation must be provided during tests to ensure satisfactory inking of the specimens. The solids concentration in inks manufactured to BS 4069 should be 0,8 to 3·2 % by volume, but with fluorescent inks the solids content is approximately one tenth of these values. Methods of determining the solids content of magnetic inks are detailed in BS 4069. Magnetic ink should be discarded if it becomes diluted by solvents or contaminated with oil or any foreign substance likely to reduce its effectiveness as a detecting medium.

2.3.2 Fluorescent inks are also widely used and are often specified where high sensi-

tivity is required. Inspection of a component to which fluorescent ink has been applied, should be carried out under black light.


0

Rev. Date

March 2011

Page No.

2/17

Chapter

6



6.18.3.4 MAGNETIC PARTICLE INSPECTION

3. METHODS OF MAGNETISATION

3.1 Current Flow Method. If an electric current is passed through a conductor, a magnetic flux is induced, both within the conductor and in the surrounding atmosphere, in a series of concentric circles at 90° to the direction of current flow. With steady current the strength of the internal magnetic flux is greatest at the surface of the conductor and decreases uniformly to zero at the centre, but with alternating current both the current and magnetic flux are confined to a thin layer at the surface, because of the effects of induction. Magnetization at the surface can be greater with alternating current than with direct current, but direct current has the advantage of greater depth of penetration. In practice, machines are often designed so that alternating or rectified current can be applied to a specimen, to make use of the advantages of each method.

3.1.1 Current flow machines normally provide a sustained current through the

specimen, ink being applied while current flows. The specimen is usually clamped between contact pads on a static machine, but portable units are availab le in which the contacts take the form of hand-held prods, and these are often used for checking components which are difficult to mount in a static machine. Good electrical contact is essential, and the contacts are usually provided with copper gauze pads, sufficient pressure being used to prevent arcing between the pads and the specimens. Because of the dangers of burning and possible subsequent fatigue cracking, the use of prods is often prohibited on finished parts, especially those of high tensile steel.

3.1.2 A variation of current flow magnetization is the "impulse" method, which

employs either direct or alternating current in the form of a short impulse (generally less than one second). Difficulty may be experienced in satisfactorily inking the specimen while current is f lowing, and the specimen may be immersed in a bath of magnetic ink. Alternatively, with some materials, remanent magnetism may be sufficiently strong to provide defect indications when ink is applied after current has ceased to flow. The alternating current impulse method is not often used, due to the difficulty of interrupting the current at a point in the hysteresis loop which will leave the specimen adequately magnetized.


0

Rev. Date

March 2011

Page No.

3/17

Chapter

6




3.1.3 For testing purposes it is usual to apply a sufficiently heavy current to give a

satisfactory magnetic flux in the specimen, and to use a low voltage to safeguard the operator. As a rough guide to the basic current setting to use, most steels can be satisfactorily tested using an alternating current of 500 A rms per inch diameter or, for specimens of irregular shape, 150 A rms per inch of periphery. Some steels, e.g. nickel-chrome steels, may require a h igher magnetizing force due to their low permeability. Current values for irregular shaped components should be decided by fixing an artificial defect to the area required, applying ink, and varying current value until a satisfactory indication is obtained.

NOTE: The effective current value with regard to magnetization is the peak value. Ammeters do not usually record the peak value however, and testing techniques must state whether the current values specified are rms (root mean square) or peak. It is normally assumed that an ammeter reading rms is fitted to an a.c. machine, and an ammeter reading mean current is fitted to a rectified a.c. or constant potential d.c. machine. Current values producing a magnetic flux equivalent to that produced by 500 Arms, a.c., with these types of ammeter fitted, are: ---

d.c. – 710 A half-wave rectified a.c. – 225 A full-wave rectified a.c. – 450 A

If a peak-reading ammeter is fitted to an a.c. machine, the current value should be the same as for d.c. (i.e. 710 A). In cases where the wave form is unknown, the relationship between peak and average· values must be determined empirically, and the current adjusted accordingly.

3.1.4 The passage of a heavy current will have a heating effect on the specimen, particularly when direct current is used. This could cause burning in specimens such as thin tubes, and possibly have an adverse effect on any heat treatment previously applied. The duration of each test should, therefore, be limited to as short a time as possible, consistent with satisfactory inking of the specimen.

3.2 Induction Methods. In all induction methods, the magnetic field external to the

current-carrying element is used to induce a magnetic flux in the specimen.


0

Rev. Date

March 2011

Page No.

4/17

Chapter

6




3.2.1 Magnetic Flow Method. Figure 1 shows the arrangement of a typical magnetic

flow machine, the specimen being clamped between adjustable poles in the magnetic circuit of a powerful electromagnet. Good contact between the poles and specimen is essential; otherwise a marked lowering of the field strength will result. Laminated pole pieces are often used to ensure that good contact is maintained with specimens of curved or irregular shape, and in some portable equipment which employ a permanent magnet; contact is obtained through a number of spring-loaded pins.

(i) The magnetizing force required to carry out a test using a magnetic flux machine,

will depend on the length, cross-section and permeability of the yoke, the number of turns of the windings, and the magnetic characteristics of the test piece. No set current value would be suitable with all machines, and tests should be conducted to ascertain the current value which will ensure magnetization just below the saturation level. Saturation is indicated by a heavy build-up of magnetic ink at the ends of the specimen, or an overall coating on its surface. In all tests the cross-sectional area of the pole pieces should be greater than that of the specimen, but the maximum cross- sectional area which can be tested will

Figure 1 MAGNETIC FLOW MACHINE


0

Rev. Date

March 2011

Page No.

5/17

Chapter

6




normally be stated in the operating instructions for a particular machine. (ii) To ensure that the strength of the magnetic flux in a specimen is sufficient to

reveal defects during a test, it is common practice to employ portable flux indi-cators. These may take the form of thin steel discs containing natural cracks, which, when attached to the surface of a specimen during a test, will give an indication of flux strength and also, with some indicators, the flux direction.

(iii) With many machines it is easy to over-magnetize, particularly when carrying out

tests on small specimens. If the machine does not have controls for adjusting the energizing current, a reduction in magnetic flux can be achieved by inserting nonmagnetic material between the pole pieces and the specimen.

Figure 2 THREADING BAR METHOD


0

Rev. Date

March 2011

Page No.

6/17

Chapter

6




(iv) Magnetic flow machines are generally designed to operate with direct current, the magnetizing coil containing a large number of turns of wire and carrying a current of a few amps only. This type of coil would be unsuitable for use with alternating current, since the coil would have too much inductance. If it is required to use alternating current for magnetic flow tests, the coil must be replaced by one having a few turns and carrying a heavy current.

3.2.2 Threading Bar Method. This method is used for testing rings and tubes, and is

illustrated in Figure 2. A current flow machine is used, and a conductor connected between the contact heads of the machine. Current flowing through the: conductor induces a magnetic flux in the specimen at 90° to the direction of current flow; this flux may be used to reveal defects in line with the axis on the specimen. Best results are obtained when the air gap is smallest, i.e. the conductor is only slightly smaller than the internal diameter of the specimen, but a larger air gap is often necessary in order to permit examination of the interior surface.

(i) A symmetrical flux may

be obtained in the specimen by inserting non-conducting spacers between the conductor and the specimen, but this is not essential except to prevent burning should the conductor overheat. If the shape of the item undergoing test precludes the use of a straight conductor, a heavy flexible cable may be used.

Figure 3 MAGNETISING COIL METHOD


0

Rev. Date

March 2011

Page No.

7/17

Chapter

6



6.18.3.4 MAGNETIC PARTICLE INSPECTION (ii) The basic current setting should be determined from the length of the flux path,

i.e. the outside periphery of the specimen, 100 to 200 amps per inch being a satisfactory basic setting for most steel specimens. The current required is unaffected by the length of the specimen, except that if the specimen is very long the resistance of the conductor may limit the available current.

3.2.3 Magnetizing Coil Method. A current flow machine is also used for the

magnetizing coil method. An insulated heavy gauge copper wire or strip is connected between the contact heads of the machine ,as shown in Figure 3, and formed into a coil; a.c. coils have 2-!- to 4 turns and d.c. coils 6 to 10 turns, the space between turns being less than the cross-sectional diameter of the wire in order to minimize flux leakage. The magnetic lines of force resulting from passing current through the coil will induce a magnetic flux in the specimen, in the direction of the coil axis.

(i) Components of simple shape may be placed within the coil during a test, but

satisfactory magnetization will only be obtained within the length of the coil. Difficulty may be experienced with short components, due to the de-magnetizing effect resulting from the close proximity of the free poles (i.e. the ends of the specimen), and it is often advisable to complete the magnetic circuit using a yoke manufactured from mild steel, or extend the effective length of the component with end blocks.

(ii) When components of complicated shape are being tested, it is difficult to estimate

the strength and direction of the magnetic flux in all parts of the specimen during a single test. It is often preferable to make several tests with the coil located at several positions within or around the specimen, inspecting only those parts adjacent to the coil at each position.


0

Rev. Date

March 2011

Page No.

8/17

Chapter

6



(iii) As with

the magnetic flow method, the current required depends on a number of factors, including the relative diameters of the specimen and coil, and the length/ diameter ratio of the specimen. BS M35 gives a formula for calculating the current required under specified conditions, but the most suitable values are generally obtained by experiment, and by selecting a current which gives a field strength just less than that required to saturate the material.

3.2.4 Induced Current Flow Method. Figure 4 shows the coil arrangements for this

method, in which current is induced to flow through the specimen by the action of the primary coil of a transformer. The induced current itself provides a magnetic field within the specimen, which may be used for detecting defects lying mainly in a longitudinal direction. This method is often used on ring specimens of large diameter.

4. TESTING PROCEDURES. Techniques of testing by magnetic methods are established

after preliminary tests have shown that defects can be consistently revealed in similar parts to those under test. When carrying out routine tests in accordance with a specified technique, each instruction must be carefully followed in order to obtain satisfactory results. The full test procedure consists of degreasing,

Figure 4 INDUCED CURRENT FLOW METHOD


0

Rev. Date

March 2011

Page No.

9/17

Chapter

6



magnetizing, application of magnetic ink or powder and interpretation of indications, this

process being repeated for each test specified on the technique sheet and concluding with final demagnetizing and cleaning. The use of a hand lens of low magnification is normally specified for the examination of defects.

4.1 General Considerations. Before carrying out a test the equipment should be

checked to ensure that it is functioning properly. The technique sheet (see paragraph 5) will usually specify the capacity of the machine required for a test, and stipulate the type of magnetic ink or powder to use. An initial test, using it specimen containing known defects, may be carried out to verify that these defects can be revealed. Alternatively, in the absence of a cracked specimen a test may be carried out using a "portable crack" taped to the surface of the specimen. This often consists of a thin strip of material in which a crack has been artificially induced, and may be used as a guide for acceptance or rejection of the specimen under test. Equipment is usually checked with standard test pieces.

4.1.1 Good lighting is essential for examining the specimen. Good daylight provides

the best illumination for normal inks, but fluorescent lighting, free from highlights and of correct intensity, is a su itable substitute. When using fluorescent inks, black light is essential and daylight should, as far as possib le, be excluded from the viewing area; efficiency of the black light source should be checked periodically (BS 4489).

4.1.2 Adequate bench space should be provided adjacent to the testing machine and,

where the nature of the work permits, should be away from noisy or otherwise distracting locations.

4.1.3 When specimens are tested in batches and set aside in a magnetized condition

for subsequent examination, they should not be permitted to come into contact with one another, or with any other magnetic material, such as steel-topped benches or steel brackets, until the examination has been completed. If specimens do come into contact with other magnetized objects a local dis-arrangement of the magnetic field may occur, giving an effect similar to that obtained with a real defect.

4.2 Selection of Method. In cases where a technique of examination has not been

specified, tests must be made to ensure that defects in the specimen can be satisfactorily revealed.


0

Rev. Date

March 2011

Page No.

10/17

Chapter

6



4.2.1 Factors to be considered are the size and shape of the specimen, and the

capacity of the machines available. Changes of cross-section in a component will result in variations in the intensity of magnetization through the component, requiring several tests using different current settings at each change of cross-section. The shape of a component may also modify the distribution of magnetic flux and result in misleading indications in the ink pattern. Examples of difficult specimens are toothed gears, turbine blades with fir tree roots and threaded components, where over-magnetization may result in build-up of iron oxide at the extremities, and cause defects to be hidden. This type of component may often be examined using a remanent magnetism technique, a d.c. supply being used with fluorescent ink; the part should be gently swilled in paraffin after application of the ink to clear the background, but retain any defect indications.

4.2.2 Since the majority of specimens must be tested for longitudinal and transverse

defects, both current flow and magnetic flow tests are normally required; both tests may be carried out on a single universal machine.

4.2.3 Table 1 gives guidance on the most suitable methods of testing materials of

various simple shapes; components of complicated shape may require special techniques. Tests using flux detectors and portable cracks will usually permit a satisfactory technique to be established, however, and great difficulty is not often experienced.


0

Rev. Date

March 2011

Page No.

11/17

Chapter

6




TABLE 1

Specimen Suitable Test Methods

Bar Current flow for longitudinal defects. Magnetic flow for transverse defects. Magnetizing coil for transverse defects.

Tube Threading bar for longitudinal defects. Magnetic flow for transverse defects. Current flow for longitudinal defects. Magnetizing coil for transverse defects.

Ring Threading bar for defects in line with ring axis, and radial defects. Current flow or induced current flow for circumferential defects.

Plate Current flow or current flow using prods for both longitudinal and transverse defects.

Disc Current flow or current flow using prods, with the disc rotated 90° between successive tests.

Sphere Current flow or current flow using prods, sphere being rotated to reveal any defects. Magnetic flow or magnetizing coil may also be used if flux path is extended using steel extension pieces.

4.3 Preparation. Specimens should be free from dirt, grease or scale, since these may

hide defects and contaminate the magnetic ink. Scale may usually be removed by abrasive blasting or approved chemical methods, and trichloroethylene or other suitable solvents are normally used for degreasing when the parts are being tested away from their assembled positions. Trichloroethylene should not be used for cleaning parts in situ, due to the health hazard. It is not usually necessary to remove paint or plating except to provide good electrical contact for the current flow process.

NOTE: The fluorescent properties of certain magnetic inks may be dimin ished by chemical reaction with acids. When acid pickling is used as a cleaning process, care is necessary to ensure that all traces of acid are washed off.

4.3.1 Preparation of the specimen should also include demagnetization. Magnetization

may have been induced by working, by machining in a magnetic chuck, or by lying adjacent to magnetized components or material. In the case


0

Rev. Date

March 2011

Page No.

12/17

Chapter

6



of raw material, magnetization may be removed by heating to a temperature above

the Curie point for the material, but generally, for f inished parts, it must be removed as detailed in paragraph 4.8.

4.3.2 Apertures such as oil ways and deep tapered holes, which do not form part of

the area to be examined, should be plugged to prevent the intrusion of ink, which may be difficult to remove.

4.4 Magnetization. Components of simple shape will normally require magnetizing

in two directions, by a selection of the methods described in paragraph 3, so that defects of any orientation will be revealed. Components of complicated shape may require further magnetization in selected areas to ensure complete coverage. A component"--should normally be demagnetized between each test, to remove the effects of residual magnetism, which could cause spurious indications.

4.5 Inking. Except where remanent magnetism is used to reveal defects (paragraph

3.1.2), magnetic ink should be applied gently, immediately before and during the period of magnetization. With a.c. machines the magnetic flux should be applied for at least three seconds to allow time for the ink to build up at defects, but d.c. machines are often fitted with a time switch which limits the application of flux to between t and I second. When the immersion method is used, extreme care is necessary during removal of the specimen from the bath, in order to avoid disturbing the magnetic ink and any indications of defects which it may show.

4.6 Interpretation of Indications. Particles of magnetic ink are attracted to flux

leakage fields, and these may occur at defects, brazed joints, the heat affected zone in welds, or sudden changes of section. The presence of a sudden build-up of ink on a specimen is not, therefore, necessarily an indication of a crack, inclusion or similar discontinuity, and experience is essential in interpreting the indications produced by a test.

4.6.1 Cracks are revealed as sharply defined lines on the surface of the specimen, the

magnetic particles often building up into a ridge which stands proud of the surface.


0

Rev. Date

March 2011

Page No.

13/17

Chapter

6



4.6.2 Subcutaneous defects such as may occur during manufacture of the material,

will be more blurred than surface cracks. Non-metallic inclusions are often revealed by a diffuse clustering of magnetic particles, but may sometimes give an indication which is as sharp ly defined as a crack.

4.6.3 Grinding cracks are usually readily identified, and consist of a pattern of

irregular lines over the affected area, or, on small rad ius bends or teeth, they may appear as short paralle l lines.

4.6.4 Tool marks may g ive an indication similar to cracks, but the bottom of a tool

mark can usually be seen with the aid of a hand lens with approximately 5x magnification, whereas cracks are usually deep and narrow.

4.6.5 Localized magnetic flux resulting from ineffective demagnetization, or careless

handling after a specimen has been magnetized, may give indications known as magnetic writing. Careful demagnetizing and retesting will show whether the magnetic writing is spurious, or an indication of a real defect.

4.6.6 Excessive magnetization causes furring, and magnetic particles tend to follow

the grain flow, giving the appearance of clusters of inclusions. The remedy is to reduce magnetization when testing areas of reduced cross-section.

4.6.7 Changes in permeability within a specimen, such as may occur at welds, may

give misleading indications. Magnetic detection methods may not be suitable in these instances, and radiography may have to be used.

4.7 Recording of Defects. Defects are normally marked with grease pencil or paint

for future reference, but it may be necessary, for record purposes, to preserve the indications obtained in a test, either on the specimen or as a separate permanent record.

4.7.1 If the magnetic ink has an oil based carrier, the specimen should be drained and

dried or, alternatively, another test may be carried out using an ink containing a volatile carrier flu id. If dry powder is used no preparation is necessary.


0

Rev. Date

March 2011

Page No.

14/17

Chapter

6



6.18.3.4 MAGNETIC PARTICLE INSPECTION 4.7.2 In cases where the specimen is to be retained, it should be gently sprayed with

quick-drying lacquer or covered with a transparent adhesive film, care being taken not to disturb the surface indications.

4.7.3 If a separate permanent record is to be retained the specimen may be photo-

graphed, or one of the following actions taken:-

(i) The indications may be covered with a transparent adhesive tape, which may then be peeled off and applied to a paper or card of suitably contrasting color, to show the defects.

(ii) A strippable adhesive coating may be gently sprayed on to the surface of the

specimen. When carefully removed, this coating will retain the indications of defects, and these may be viewed on the surface which was in contact with the specimen.

(iii) The specimen may be heated and dipped in a thermosetting plastic powder

material. When cured and stripped off, this material may be viewed as in (ii) above.

4.8 Demagnetization. There are a number of reasons why specimens should be de-

magnetized before, during or after magnetic particle testing. These include the effects of magnetic writing (see paragraph 4.6.5), the difficulty which would be experienced in any subsequent machining operation due to the adherence of swarf, bearing wear due to the adherence of fine metallic particles, and interference with the aircraft magnetic .compasses. A specimen should, therefore, be demagnetized before starting tests, between tests which involve a change in flux direction, and after tests have been completed.

4.8.1 The most commonly used demagnetizer is an aperture type of coil carrying an

alternating current. The specimen should be placed inside the energized coil and withdrawn a distance of at least 11 meters (5 feet) along the coil's axis with the current switched on, or may be placed inside the coil and the current gradually reduced to zero. Ideally, the coil should be just large enough to accept the specimen.


0

Rev. Date

March 2011

Page No.

15/17

Chapter

6



4.8.2 If a demagnetizing coil is not available the crack detecting machine may be

used. Alternating current from the machine may be passed through two or three turns of heavy cable, which may be used in the same way as a demagnetizing coil. Alternatively, a suitably equipped direct current electromagnet machine may be used, the specimen being placed between the poles and the current being gradually reversed and reduced simultaneously to zero.

4.8.3 For demagnetizing parts in situ an alternating current yoke is normally used. This consists of a coil wound on a laminated yoke, which is used in a stroking action on the specimen. The strokes should always be in the same direction along the specimen and the yoke should be moved away in a circ le on the return stroke.

4.8.4 After demagnetizing, the specimen should be removed from the vicinity of the demagnetizing coil, the testing machine, or any other magnetized material.

4.9 Tests for Demagnetization of Parts. Any components which are manufactured

from steel and liable to affect the aircraft compass, should be demagnetized and a test for remanent magnetism carried out before assembly in the aircraft. The standard test for remanent magnetism in aircraft parts is the deflection of a magnetic compass needle under controlled conditions, but an alternative method, such as the use of a flux meter, may be permitted, and suitable limits prescribed.

4.9.1 The test consists of placing a suitable magnetic compass in a position away from all stray magnetic influences, and slowly rotating the component at a position along the east/west axis of the compass. The distance of the component from the compass should be specified for the test, and should be the same as the distance from the aircraft compass to the installed component. Deflection of the compass needle by more than 10 will require the component to be demagnetized again and the test to be repeated.

4.10 Final Cleaning. When a component has been accepted following a magnetic

detection test, all traces of detecting ink, contrast paint or temporary marking should be removed. Wiping or washing in solvent or immersion in an approved degreasing agent are the methods normally use. During cleaning, any plugs or blanks fitted during the preparation for the test should be removed. A temporary rust protective should be applied after cleaning, and the part should be identified in accordance with the appropriate drawing, to indicate that magnetic flaw detection has been satisfactorily carried out.


0

Rev. Date

March 2011

Page No.

16/17

Chapter

6



6.18.3.4 MAGNETIC PARTICLE INSPECTION 5. TECHNIQUE SHEETS. A technique sheet is a document detailing all the magnetizing

operations to be performed when inspecting a particular component by the magnetic particle method. It may be accompanied by an illustration of the component and by instructions applicable to all magnetic particle tests, such as the methods of cleaning and demagnetizing to be used.

5.1 A technique sheet should show all the relevant details for each magnetizing

operation, including type of equipment, strength and form of current, acceptance standard, contact areas, positions of flux detectors, type of coil, size of threading bar, and test pattern, as appropriate to the particular test. It is recommended that the symbols used in BS M35 should be used on all technique sheets and, where appropriate, on related drawings or sketches.


0

Rev. Date

March 2011

Page No.

17/17

Chapter

6


6.18.4 COMPOSITE REPAIR

Philippine Aerospace Development Corporation’s method on performing composite repairs will be based on applicable Structural Repair Manual from the manufacturers and current publication that may be supplied by the customer.

It is important that the assigned personnel has undergone the Composite Repair Training and knowledgeable in the repair process.

It is also important that the personnel is capable of correctly interpreting the repair procedures required by Structural Repair Manual.

SECTION NO. 6.18.4 Rev. No.

0

Rev. Date

March 2011

Page No.

1/1

Chapter

6


CHAPTER 7

CALIBRATION PROCEDURE

SECTION NO. 7.0 Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

7


CALIBRATION PROCEDURES 7.1 CALIBRATION PROCEDURE FOR VERNIER CALIPER

CALIBRATION ROOM ENVIRONMENTAL CONDITIONS

1. Room temperature controlled to standard condition 20 to 25 deg. C. 2. Humidity not more than 70%. 3. Strictly “NO SMOKING”.

APPARATUS

Vernier Caliper, Gauge Blocks – Grade A, Magnifying Glass and Gauge Block Holder.

PROCEDURE

1. Check for the cleanliness of all the apparatus. 2. Check for any damage on the vernier caliper. If any damage is observed, make

necessary steps to remedy or to dispose the vernier caliper. 3. The slider shall slide smoothly without slackness throughout the entire stroke. 4. Make sure that the reference lines of scales coincide when jaws are closed, and that no

clearance is observed in between the jaws when exposed to the light. 5. When a slight is observed, the clearance may be estimated as 3-5 m. 6. The parallelism of the faces for internal measurement may be checked by means of a

micrometer. 7. The accuracy of the vernier caliper may be checked with gauge block combinations of

every 10 m. Take readings on a series of gauge blocks for the difference between the readings and the size of gauge block.

8. Enter the readings in the vernier caliper test report. 9. Repeat procedure 7 and 8 three (3) times. 10. Take the average readings of the three (3) measurements performed and calculate the

errors. a. Average reading = Test 1 + 2 + 3 ÷ 3 b. Error = ( vernier caliper reading ) – (size of gauge block ) 11. Graph the caliper reading error. 12. Return caliper to service.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

7



7.2 CALIBRATION PROCEDURE FOR DIAL GAUGES


1. Room temperature controlled to standard condition 20 to 25 deg. C. 2. Humidity should not be more than 70%. 3. The room shall be “NO SMOKING”.

IMPORTANT

Leave all the necessary calibrating instruments in the controlled calibration room for at least an hour before performing calibration.

APPARATUS

Dial Gauge, Gauge Blocks – Grade “A”, Measuring Plate

PROCEDURE

1. Check for the cleanliness of all the equipment. 2. Check for appearance and functions.

a. The plating and coating on all parts shall be free from peeling or rusting. b. All parts shall be free from arising disorder during practical use at any changes

of temperature and humidity on usual use condition. c. Stamping and graduations shall be free from defects. d. Covering plate shall be tightly fixed to the outside of the frame. e. The dial gauge shall be in good condition and free from slackness when

moved several times throughout the entire stroke. f. When the spindle is pressed, the long needle shall rotate in clockwise

direction. g. The clearance between the head of the long needle and the graduation plate

must be at least 1.0mm and shall be uniform throughout the rotation.


0

Rev. Date

March 2011

Page No.

1/3

Chapter

7




h. In case of reading the whole movement of spindle by the rotation of long needle, the reference point of the measurement shall be 0.2mm removed point of the measurement shall be 0.1 mm removed point from the point of repose of long needle and the terminus shall be at 0.2mm minimum passing through the prescribe measuring range respectively.

NOTE: For dial gauges, whose measuring range is from 1-5 mm, reference point shall be 0.02 mm removed point from the point of repose of the long needle and the terminus shall be at 0.05 mm.

i. The movement of the outside frame shall be smooth and the plate of graduation shall be fitted at any place at will.

j. The fit of the short needle shall be constructed to show the rotation number of the long needle or to show the available distance of the spindle.

k. When there is a limit-compass needle, the dial gauge shall be constructed so as to be adjusted easily, accurately and immovable during measurement.

l. The clamping device shall provide positive locking of outside frame causing no error in measurement.

3. Hold dial gauge on stand. 4. Place the measuring face on the measuring plate in a vertical position. 5. Rotate the spindle five (5) times hastily and mildly within the measuring range and

take the largest value of difference between readings. 6. Zero set the dial gauge. 7. Place gauge block on the measuring plate and bring the measuring face in contact

vertically. 8. Take readings on the difference of indication between dial reading and the size of

gauge block by removing the series of gauge block before and behind, to the left and right.


0

Rev. Date

March 2011

Page No.

2/3

Chapter

7




Note: The permissible design accuracy of the dial gauge in the measuring scope of 1-5 mm is 0.3m. For the ranges 5 – 10 mm of 3.00 m is acceptable.

9. Enter the readings in dial gauge test report. 10. Repeat Procedures No7. to 9 three (3) times. 11. Take the average readings of the three (3) measurements performed and calculate

error. Average Reading = Test 1 + 2+ 3 ----------------- 3

1. Error= (Dial Gauge Ave. Reading ) – (Size of Gauge Block)

12. Graph the dial gauge reading error.


0

Rev. Date

March 2011

Page No.

3/3

Chapter

7


CAILBRATION PROCEDURE

7.3 CALIBRATION PROCEDURE FOR DIFFERENTIAL PRESSURE GAGE


1. Room temperature controlled to standard condition 20 to 25 deg. C. 2. Humidity not is less then 70%. 3. The room shall be “NO SMOKING”.

CALIBRATION EQUIPMENT

Differential pressure Gage, Deadweight Pressure Tester-AMETEK Model No. 10-5525, Set of Deadweight, Pressure Tester Comparator-BARFIELD Instrument Type 2311F (Optional), Fittings.

PROCEDURE

1. Check valid ity of the Master Reference. 2. Check for cleanliness of all the measuring equipment. 3. Check integrity of all units to be calibrated. If any damage is observed, make

necessary steps to remedy or to dispose the unit. 4. Insert appropriate fittings to the gage and connect High pressure valve to the

pressure tester. Leave Low pressure side vented to the atmosphere. 5. Place weight and purge/bleed the system by applying a slight pressure at the source.

Repeat bleeding process as many times as possib le to completely release residual air within the system.

6. After bleeding, select at least five (5) test points within the normal operating range for which the gage is used.

7. Slowly, apply pressure on the dead weight pressure tester while watching the dial/pointer for smooth action up to the scale reading. Approach each test reference from a lower value, do not overshoot and come back.


0

Rev. Date

March 2011

Page No.

1/2

Chapter

7




NOTE:

1. Pressure tester piston travel should not exceed the required travel limits. A band on the piston indicates maximum piston travel.

2. For data reliability, in case the gage to be calibrated is old, use Pressure Tester

Comparator (Barfield Instrument Type 2311F) together with the Deadweight Pressure Tester. Connect Low pressure line of the gage to the Pressure Tester Comparator and assign a certain low pressure value. Compare the difference between the High and Low pressures to the reading on the gage undergoing calibration. Use the same low pressure value during the entire calibration process as constant.

Pressure gage reading “MUST” be the same with the Master Reference or within 2% of the scale reading. Record the result on the test report form.

4. Repeat Procedure No.7, setting to the next selected value and so on, progressively. 5. Compute percentage error by averaging three (3) test values on each selected test

points.

%ERROR = Reference Setting – Average Gage Value ---------------------------------------------------- X 100 Reference Setting 6. Remove and replace all calibration deal. Indicate tool number or control number, date

of calibration, next due date and impress inspection stamp. Seal all gage openings. 7. Return differential gage to service.


0

Rev. Date

March 2011

Page No.

2/2

Chapter

7



7.4 CALIBRATION PROCEDURE FOR DIFFERENTIAL PRESSURE GAGE (INCHES OF KEROSENE)

CALIBRATION ROOM ENVIRONMENTAL CONDITIONS 1. Room temperature controlled to standard condition 20 to 25 deg. C. 2. Humidity not be more than 70%. 3. The room shall be “NO SMOKING”. IMPORTANT Leave all the necessary calibrating instruments in the controlled calibration room for at least an hour prior to calibration. APPARATUS

Differential Pressure Gauge (Inches of Mercury), Dry Air (Nitrogen), Water Manometer, Mercury Manometer, Pressure Generator (Meriam Model A-841), Fitting & Hoses. CONVERSION FACTORS

1 in H2O = 0.738 in. Hg. = 1.2195 in. Kerosene 1 in Hg. = 13.60 in. H2O = 345.44 mm. H2O 1 in Kerosene = 0.03 psia = 0.061 in. Hg


0

Rev. Date

March 2011

Page No.

1/3

Chapter

7



7.4 CALIBRATION PROCEDURE FOR DIFFERENTIAL PRESSURE GAGE (INCHES OF KEROSENE)

PROCEDURE

1. Check for cleanliness of all the measuring equipment. 2. Check integrity of all units to be calibrated. If any damage is observed, make

necessary steps to remedy or to dispose the unit. 3. Check manometer mounting for being absolutely vertical 4. Place Pressure Generator operating handles on the most rearward position. Adjust

manometers to zero (0) scale reading, with no pressure applied. Slide scale or adjust liquid level.

NOTE: With mercury, read to the highest indicated liquid level and with any other liqu id, i.e. water, the lowest visible level should be used.

5. Insert appropriate fittings. Connect low pressure line from the gate to the water manometer and high pressure line to the mercury manometer.

6 Turn the Pressure Generator operating handle in a clockwise direction until mercury

level reaches 1.0 in. Hg. Open gate valve of the nitrogen cylinder and slowly turn-on the control handle of the water manometer until pressure reaches 345.44 mm. H2O. Shut off nitrogen cylinder valve and turn-off water manometer control handle. A zero (0) pressure indication will be observe in the gage to be calibrated.

7. Apply approximate full scale pressure at the high pressure source. 8. Stabilized for at least five (5) minutes. A gradual drop in the manometer level will

indicate a leak at some point in the system. Troubleshoot if necessary, no leaks are allowed.

9. After leak test, release pressure by loosening first the high pressure fitting followed by the low pressure fitting in the differential pressure gauge.


0

Rev. Date

March 2011

Page No.

2/3

Chapter

7




(INCHES OF KEROSENE) 10. Replace Pressure Generator operating handle on the rearward position. Tighten

both high and low fittings and repeat procedure no. 6. Select at least five-(5) test point within the gage normal operating range.

11. Slowly apply pressure on the high-pressure line (mercury) until it reaches the

selected test reference.

NOTE: Pressure in the Water Manometer should “ALWAYS” be maintained at 345.44 mm. H2O throughout the entire calibration cycle. Pressure gage reading “MUST” be the same with the Master Reference or within 2% of the scale reading.

12. Record the result on the test report form. 13. Repeat procedure no. 11 and 12, setting to the next selected test value and so on, progressively. 14. Compute the percentage error by averaging the three (3) test values on each selected test points.

%ERROR= Reference Setting – Average Gage Value -------------------------------------------------- x 100 Reference Setting

15. Remove and replace all calibrating decal. Indicate tool number or control number, date of calibration, next due date, and impress inspection stamp. Seal all gauge openings. 16. Return pressure gauge to service.


0

Rev. Date

March 2011

Page No.

3/3

Chapter

7



7.5 CALIBRATION PROCEDURE FOR MICROMETER


1. The temperature of the calibration room shall be maintained and constantly monitored to

20 C (68 F) +- ½ C. Humidity standard conditions.

2. The room shall be “NO SMOKING”.

IMPORTANT

Leave all the necessary calibrating instruments in the controlled calibration room for at least an hour before performing the calibration.

APPARATUS

Micrometer, Micrometer Stand, Gauge Block – Grade A, Magnifying Glass and Optical Parallels.

PROCEDURE

1. Check for the cleanliness of all the measuring equipment. 2. Check for the appearance and functions.

a. The plating and coating on all parts shall be free from peeling or rusting. b. Stamping and graduations shall be free from defects. c. The screw threads shall be well engaged to provide smooth travel of spindle

throughout the entire stroke without slack. d. The clearance between thimble and sleeve shall be uniform and any deflection caused

by turning the thimble shall be minimum. e. The beveled edge of the thimble shall be finished so as to provide correct reading of

the sleeve graduation f. The ratchet or friction stop shall rotate smoothly. g. The clamping device shall provide positive locking of spindle causing no error in

measurement.


0

Rev. Date

March 2011

Page No.

1/3

Chapter

7




3. Flatness of measuring face Bring the optical parallel into close contact with the measuring face and take reading of the number of red interference fringes by white light. A band represents the flatness of 0.32m. The permissible maximum flatness of measuring face is two (2) bands for range up to 250 mm. and four (4) bands for range over 250 mm. Enter the readings in the micrometer test record

4. Parallelism of the measuring faces The parallelism of the measuring faces of the micrometer is tested by means of a set of four optical parallel faces and thickness that differ by approximately a quarter of a pitch so that the test is carried out at four positions of a complete rotation of the micrometer spindle face. These optical parallels are placed in turn between the measuring faces under the pressure of its ratchet or friction drive. By carefully moving the optical parallel between the faces, the number of interference bands visib le on one face should be reduced to a minimum and those on the opposite face then be counted. This procedure should be repeated with optical parallel in the set.


0

Rev. Date

March 2011

Page No.

2/3

Chapter

7




A band represents the parallelism of 0.32m. and in no case should the total number of bands exceed eight. The same method may be use for testing the parallelism of the faces of larger micrometers. In this case, two of the optical parallels are the wrung on to the measuring faces of a suitable combination of gauge blocks and the whole combination thus formed is used as a parallel-ended test pieces between the measuring faces.

Enter the readings in the micrometer test record.

5. Overall Accuracy

The accuracy of micrometer is usually checked by taking readings on a series of gauge blocks. a. Hold a micrometer by a micrometer stand. b. Zero set the micrometer c. Take readings on a series of gauge blocks for the difference between the readings

and the size pf gauge blocks.

Error = (micrometer reading) - (size of gauge block) Series of gauge block for testing micrometer a. For metric measurement (mm) 1.0, 2.0, 3.0, 4.0, 5.1, 7.7, 10.3, 12.9, 15.0 17.6,

20.2, 22.8 and 25.0 b. For English measurement (inch) 0.050, 0.119, 0.139, 0.150, 0.250, 0.350, 0.450,

0.550, 0.650, 0750, 0.850 and 1.00

6. Enter the readings in the micrometer test report. 7. Repeat procedures 5 and 6 three (3) times.

8. Take the average readings of the three (3) measurements performed and calculate the error.

a. Average reading = (Tests 1+2+3) / 3 b. Error = (micrometer reading) – (size of gauge block)

9. Graph the micrometer reading error 10. Return micrometer to service.


0

Rev. Date

March 2011

Page No.

3/3

Chapter

7



7.6 CALIBRATION PROCEDURE FOR PRESSURE GAUGE - ABSOLUTE


1. Room temperature controlled to standard condition 20 to 25 deg. C. 2. Humidity not be more than 70%. 3. The room shall be “NO SMOKING”.

IMPORTANT

Leave all the necessary calibrating instruments in the controlled calibration room for at least an hour before performing the calibration.

APPARATUS

Pressure Gage, Deadweight Pressure Tester, Pressure Tester Comparator, Set of deadweights, Fittings.

PROCEDURE

1. Check valid ity of the Master Reference. 2. Check for cleanliness of all the measuring equipment. 3. Check integrity of all unit to be calibrated. If any damage is observed, make necessary steps to remedy or to dispose the unit. 4. Insert appropriate fittings to the gage and connect pressure gage to the pressure tester. 5. Place a weight on the tester. Apply pressure and open the drain valve to release pressure

and fluid. Repeat operation as many times as possible to release residual air within the system (Bleeding Procedure).

6. After bleeding, select at least five (5) test points within the normal operating range for which the gage is used.

7. Slowly, apply pressure on the deadweight pressure tester while watching the dial/pointer for smooth action up to the scale reading. Approach each test reference from a lower value, do not overshoot and come back.


01

Rev. Date

08 Aug. 13

Page No.

1/2

Chapter

7



7.6 CALIBRATION PROCEDURE FOR PRESSURE GAUGE - ABSOLUTE

NOTE:

1. Travel of the pressure tester piston travel should not exceed the required travel limits. A band on the piston indicates maximum piston travel.

2. When using the Pressure Tester Comparator, always set the condition on gage to be calibrated and compare with the reading on the master reference.

Pressure gage reading “MUST” be the same with the deadweight tester or within 2% of the scale reading. Record the result on the test report form. 8. Repeat Procedure No.7, setting to the next selected value and so on, progressively. 9. Compute percentage error by averaging three (3) test values on each selected test

points. %ERROR= Reference Setting – Average Gage Value --------------------------------------------------- X 100 Reference Setting 10. Remove and replace all calibration deal. Indicate tool number or control number, date of

calibration, next due date and impress inspection stamp. Seal all gage openings. 11. Return differential gage to service.


01

Rev. Date

08 Aug. 13

Page No.

2/2

Chapter

7



7.6 CALIBRATION PROCEDURE FOR TORQUE WRENCH


1. The temperature of the calibration room shall be maintained and constantly

monitored to 20 – 25 deg. C

2. Humidity not more than 70%

3. Strictly “NO SMOKING” area

APPARATUS

Torque wrench tester, torque wrench, drive adapters

PROCEDURE

1. Check cleanliness of all apparatus.

2. Check integrity of the unit to be calibrated.

3. Insert appropriate adapter to the torque tester

4. Set torque tester reaching to “0”.

NOTE 2: Select at least five (5) test points on the torque wrench from minimum to maximum setting.

5. Set torque wrench to minimum scale setting, then insert drive to the adapter horizontally.

6. Slowly pull down handle until click sound is heard, simultaneously observe torque

tester reading. Torque tester reading “MUST” be the same to the torque wrench setting or within 4% of the scale reading. Record the reading on test report form.


01

Rev. Date

08 Aug. 13

Page No.

1/2

Chapter

7



7.6 CALIBRATION PROCEDURE FOR TORQUE WRENCH

Note 3: Dial type toque wrenches are check by direct reading comparison to the tester indicator – tolerance of +- 2% is acceptable.

7. Repeat procedure No. 6, setting torque to the next selected torque to the next

selected torque wrench test value and so on, progressively.

8. Compute the percentage error by averaging the three (3) test values on each selected test points.

%ERROR= Tester Setting Value – Average Wrench Value X 100 Tester Setting Value

9. Remove all calibration decal and replace. Indicate tool number or control number,

date of calibration, next due date and impress inspection stamp.

10. Return torque wrench to service.


0

Rev. Date

18 Aug. 13

Page No.

2/2

Chapter

7


CHAPTER 8

QUALITY SYSTEM PROCEDURES


0

Rev. Date

March 2011

Page No.

Chapter

8


QUALITY SYSTEM PROCEDURES

8.1 OVERVIEW:

The established Quality System must be implemented and maintained as an effective means of ensuring that the services and products provided by conform to specified regulatory requirements.

The Quality System places heavy emphasis on the prevention of problems rather the dependence on detection once the problems have arisen.

OBJECTIVE:

1) To insure good maintenance practices and compliance with all re levant requirements in these regulations such that aircraft and aeronautical products may be properly returned to service.

2) To monitor compliance with and adequacy of the procedures and by providing a system of inspection to ensure that all maintenance is properly performed.

3) Compliance monitoring shall include a feedback system to the designated management person or group of persons directly responsible for the quality system and ultimately to the accountable manager to ensure, as necessary, corrective action.

4) It shall be sufficient to review all maintenance procedures as described in the Procedures Manual in accordance with an approved program once a year for each aircraft type maintained.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8


8.2 QUALITY AUDIT OF ORGA NIZATION PROCEDURES

8.2.1 QUALITY AUDIT PROCEDURES

Quality is the responsibility of all persons in the organization who play a part in the accomplishment of work activities undertaken by the company. The license /authorization holder forms a key link in the chain of activities by virtue of his expertise and responsibility towards airworthiness under the authority granted to him by the Regulatory Authorities and Quality Assurance Division. The Audit System provides the basis for the establishment of conformity to regulatory requirements and accepted standards of work under the authorization ratings granted by the Civil Aviation Authority of the Philippines.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8


QUALITY AUDIT OF ORGA NIZATION PROCEDURES

8.2.2 FACILITY QUALITY AUDIT

Facility Quality Audit is conducted semi-annually to evaluate and ensure the effectiveness of the current quality control system thereby assuring consistent delivery of acceptable products and services at minimum cost. Audit of the facility is conduct every June and December. The audit system is extensively designed to suit the purpose thus, making it responsive to the actual needs of the facility.

The audit will be conducted by the Quality Assurance representatives using the prepared“ Sub-System” checklists. Checklists are sufficiently detailed to ensure that all maintenance functions are addressed. Each Sub-System is composed of questions designed to evaluate a particular aspect or characteristic. These questions are numbered and are assigned with a possible maximum point in accordance with the level of importance in the whole sub-system.

Audit results are submitted to concerned work center heads to correct any discrepancy found during inspection. A copy is furnished to the President for his information. Discrepancies noted during the audit are monitored, re-inspected quarterly to ensure compliance or corrective actions taken. Discrepancies corrected are then removed from the audit report and take note of the date of correction. “Open” discrepancies are reported again to the concerned work center head. It will remain “Open” until such time it is corrected. The conduct of the semi-annually evaluation is a major responsibility of the Quality Assurance Division.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.3 QUALITY AUDIT PROGRAM

The audit program shall be planned and controlled to ensure all areas are adequately monitored. To accomplish them, the updated Audit Schedule program is prepared on annual basis

In any case, all work areas and procedures will be audited quarterly.

1. Line Maintenance

2. Engine Overhaul Shop

3. Radio/Electrical/Instruments shop

4. Fuel Accessories Shop

5. Propeller & Hydraulic Shop

6. Machine Shop

7. Electrical Shop

8. Test Cell

9. Warehouse Store 3

10. NDT shop

11. Control of PME


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.4 REVIEW OF QUALITY SYSTEM

General Manager/Accountable Manager is to hold regular meeting, at least twice a year with the Director- Maintenance & Engineering Department and Quality Assurance Manager to review the overall performance of the company, and the effectiveness of the quality system.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.5 ANNUAL REVIEW OF MAINTENA NCE PROCEDURE MANUAL

On a half yearly basis, the Quality Assurance Division will review the Company’s Maintenance Procedures Manual vis-à-vis the requirements of CAAP CARP Part 6 concerning approval of the Aircraft Maintenance Organization.

This audit will monitor compliance and adequacy of the procedures to meet the relevant updates in the airworthiness requirements.

The Maintenance Procedures manual will be amended as necessary to meet new requirements.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.6 QUALITY ASSURANCE PROGRAM

The Quality Assurance Program should include procedures to ensure that corrective actions developed in response to findings. These Quality Procedures should monitor such actions to verify their effectiveness and that they have been completed. Director for Maintenance and with the Quality Assurance Division Manager in the report identifying the finding. Quality Assurance Program shall ensure that all referenced procedures remain applicable and effective and address the need for manual amendments resulting from such changes. The Accountable manager will have ultimate responsibility for ensuring, that corrective actions has been re-established compliance with the standard required by the Authority and any additional requirements established by the CAAP The Quality Assurance Program should address the need for or when the training is required by the organization and review of such training.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.7 REVIEW AND ANALYSIS OF AUDIT FINDINGS PERIODIC REVIEW

Internal audit findings are to be analyzed periodically to identify significant quality issues, recurring causal factors and or significant trends. Manager, Quality Assurance will review the data to determine if it is necessary to take additional action. Significant findings and review analysis data will be monitored and reported to the Accountable Manager.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8



8.2.8 QUALITY AUDIT REPORT

All discrepancies found during quality audit of the organization and aircraft shall be duly recorded by the auditor and findings submitted to the appropriate section for corrective actions:

Non-conformity : Must be rectified immediately within 5 working days.

Major : To be resolved in the shortest practical time frame

but not more than 15 calendar days from date of Audit Finding report.

Major : To be resolved in the shortest practical time frame but not more than 30 calendar days from date of Audit Finding report

Minor : To be addressed at earliest convenient opportunity, but not more than 30 calendar days from date of Audit Finding Report issuance.

Observation : To be addresses at the most convenient opportunity, but not more than 45 calendar days from the date of AFR issuance.


0

Rev. Date

March 2011

Page No.

1/2

Chapter

8



8.2.8 QUALITY AUDIT REPORT

1. All Internal and External Audit report conducted shall be handled by the Quality Assurance Division for distribution and compliance to the requirements.

2. Internal and External audit findings will be relayed to concerned department for their information and for the Root Cause and Corrective /Preventive action .

3. Complied AFR with the Root Cause and Corrective/Preventive Action taken must be submitted to Quality Assurance Division within the target date of compliance provided.

4. Extension request need to be requested for non-compliance before the given target date. Extension Request is one time request.

FEEDBACK SYSTEM:

The Quality system includes a feedback system to ensure that corrective actions are both identified and promptly addressed. Discrepancies and non-compliance are required to be rectify within the target date of compliance provided.


0

Rev. Date

March 2011

Page No.

2/2

Chapter

8



8.2.9 CORRECTIVE ACTION AND FOLLOW –UP

All Discrepancies shall be followed up, making sure that timely and appropriate corrective actions are taken and priority is accorded to Non-conformity and Major discrepancies, Status columns are provided against the discrepancies listed in the Non-conformance report so that all actions can be monitored.

Quality Assurance Division will forward the closed audit reports to the Accountable Manager for his information

Significant findings from internal and external audit reports are also highlighted to the Accountable Manager.

NOTE: Please refer to PADC QUALITY MANUAL for detailed Quality System Procedures


0

Rev. Date

March 2011

Page No.

1/1

Chapter

8


CHAPTER 9

TRAINING

SECTION NO. 9 Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

9


9.0 TRAINING

9.1 CERTIFYING STAFF QUALIFICATION A ND TRAINING PROCEDURES

EXPERIENCE, TRAINING AND COMPETENCE REQUIREMENTS

Certifying staff is the person who has authority to certify aircraft during transit after completion of maintenance of inspection. He must have CAAP license in Airframe and Powerplant with appropriate type of training and the line authorization approval.

AUTHORIZATION SYSTEM

Company Authorization will only be granted to persons with approved license and ratings, and comply with the requirements stated in this section. Manager –Quality Assurance Division will issue Company Certificate of Authorization individually to the suitable person recommended for such authorization. All Authorization holders will carry out his authority limitation on behalf of Phil. Aerospace Development Corporation (PADC) and will be monitored and controlled to maintain his capabilit ies standard required by the regulation. Company Certificate Authorization may be cancelled, suspend or revoked anytime as deemed by PADC. The Certificate of Release to Service (CRS) shall be only be signed by the holder of a valid CAAP license or equivalent license acceptable to authority with appropriate aircraft type authorization. The scope of work or limitation and individual’s responsibilit ies is stated in each authorization limitation in accordance to the assessment result.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

9


TRAINING

9.2 ASSESSMENT AND VERIFICATION REQUIREMENTS

Certificate of Authorization shall be issued under the following procedure:

1. Airframe and Engine – Full Authorization

a) At least 21 years of age b) Be able to understand , read and write English c) Be a holder of CAAP or equivalent License acceptable to the authority at least

six (6) months. d) Be a person who has passed and satisfactorily completed the aircraft type

training including practical experiences for which he/she is going to apply for the type of Authorization. The type of training to be conducted by a facility /school acceptable to CAAP as appropriate.

e) Be a person who has passed Human Factor Training and company procedure training

f) Must be assesses by Quality Assurance manager as being qualified.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

9


TRAINING

9.3 CONTINUATION TRAINING

The continuation training or recurrent training shall be conducted at least every two years to the Authorization Certificate Holders for the re-issue/extension of the certificate expiry date. The place to derive continuation training will be selected and implemented to comply with the requirements of the type of authorization being reissued/extended Requirements to be considered:

1. Type of training on respective aircraft or component 2. Human Factors Course 3. Current CAAP License (Airframe and Powerplant or Avionics) 4. Current training list


0

Rev. Date

March 2011

Page No.

1/1

Chapter

9


TRAINING

9.4 TRAINING PROGRAM POLICY

OBJECTIVE:

To develop the knowledge and skills of all aircraft technical personnel of the company in order to be able to perform all the required maintenance checks, troubleshoot and safety dispatch the aircraft for flight. The Training Program aims at developing technical skills through advanced instructional techniques of training, and retraining for new and existing equipment. POLICY

1. It is the policy of PADC to provide training to all personnel responsible for the performance and direct supervision of aircraft maintenance and inspection requirements of the customer’s aircraft.

2. The company training program for all personnel to be assigned to the technical aspect of the aircraft are designed primarily to aid employees in their introduction to the company, its policies, equipment and procedures. The training will further ensure that all personnel are aware of determining the adequacy of work performed and are fully informed with respect to all procedures and techniques with new equipment introduced into service.

3. The company will provide current training as necessary, which will ensure that personnel are kept up-to-date with regards to aircraft, engine, systems and procedural improvement and changes.

4. The company reserves the right to determine the requirement for and scope for specific training to be scheduled and to establish priorities relative to personnel selected. Shop supervisors are responsible for evaluation of their technician’s trainings and qualifications for work under process.

5. Qualif ied instructors may be assigned to facilitate specialized training course provided they are rated.

6. Written examination will complete the training course as applicable. One time re-examination shall be given for those who failed.


0

Rev. Date

March 2011

Page No.

1/2

Chapter

9


TRAINING

9.4 TRAINING PROGRAM POLICY

7. Designated Technical Trainers/Instructors may be assigned by the Manager, Quality Assurance to facilitate specialized training courses.

8. Written examination will complete the training course as applicable. One-time re-

examination shall be given for those who failed.

9. Training Schedule will be availab le semi –annually.

10. Training announcements with participant’s name shall be released one (1) month prior start of the class.

11. Participants per training course shall be minimum of six(6) and maximum of twenty

(20). Unless with prior approval from the Manager, Quality Assurance.

12. A failing grade will be given to a training participant if they fail to attend more that 20% of the total number of training days or hours.

Please refer to Training Manual and Procedure Manuals for details of training program.


0

Rev. Date

March 2011

Page No.

2/2

Chapter

9


TRAINING

9.5 COURSES, RATINGS AND RECURRENT TRAININGS

TRAINING COURSES:

1. AIRCRAFT MAINTENA NCE POLICIES AND PROCEDURES FAMILIARIZATION

This course is designed to provide the participants with a basic knowledge of the various requirements per aircraft type of maintenance. It includes policies, maintenance and quality policies, airworthiness rules and Civil Air Regulations and other technical services requirements.

The participants are newly hired technical and non-technical, contractual/Job Order personnel and those undergoing on-the Job Training and those personnel who’s who are assigned at maintenance organization of the company but with litt le or no work experience in aircraft maintenance or knowledge on the technical aspect requirements of the aircraft.

2. HUMAN FACTORS AND ERROR MANAGEMENT

This course is designed to provide participants the understanding on the importance of people and their contribution to the Quality and Safety culture. It will propose practical solutions that will tackle human element difficulties. The participants are technical certifying and non-certifying staff, regular, contractual, Job Order, On-The Job Training, who are assigned at the maintenance organization of the company.

3. QUALITY INSPECTION TRAINING

This course is designed to familiarize the participants of the various technical policy and procedure requirements for aircraft airworthiness and the required inspection items during the performance of all scheduled and unscheduled maintenance checks and including parts and components replacements during trouble shooting prior to aircraft release to service

The participants are A& P Licensed aircraft technical personnel assigned to handle the release of the aircraft and various routine and non-routine checks on customer’s aircraft.


0

Rev. Date

March 2011

Page No.

1/2

Chapter

9


9.5 COURSES, RATING AND RECURRENT TRAINING

TRAINING COURSES

4. ELECTROSTATIC DISCHARGE SENSITIVE COMPONENT HA NDLING FAMILIARIZATION COURSE

This course is designed to have participants an understanding of static electricity including its generation and protection required from its static discharges to the component and provide a level of knowledge for proper handling Electrostatic Discharges Sensitive Component.

5. RECURRENT TRAINING (REFRESHER COURSE)

1) All aircraft certifying staff who completed the Initial type rating course on aircraft/components and continuously working for the same aircraft/component shall have to undergo an equivalent design of recurrent training to refresh and enhance their capabilit ies and skills within the preceding 24 months.

2) The recurrent training shall include continuous training requirements comprising in-service experiences, AMO procedures and changes in the standard of aircraft and /or aeronautical products maintained.

3) In the event where in concerned personnel will not be able to attend the scheduled class due to conflict of schedule, Read and Sign process shall apply as interim compliance.

4) Refresher Course will be conducted to all technical personnel who was not able to work on a particular aircraft type/model/component he is being rated for at least six months preceding the 24 months period

6. MAINTENANCE AND PROCEDURE MANUAL FAMILIARIZATION COURSE

This course is designed to familiarize all PADC employees technical, non-technical whether regular, contractual, job order employees, regarding the procedures stated in Maintenance Procedure Manual.

7. SUSPECTED UN-APPROVED PARTS

This course is designed to have participant an understanding the importance of identifying “Un-approved Parts”, to eliminate the potential safety risk posed by un-approved parts. Certifying Staff are required to attend this course.


0

Rev. Date

March 2011

Page No.

2/2

Chapter

9


TRAINING

9.6 CERTIFICATE AND RECORDS

CERTIFICATES

Training Certificates are to be issued to all participants who has satisfactorily completed the requirement of an aircraft type training courses.

RECORDS

A record of all technical training courses conducted or coordinated by PADC shall be maintained and must be updated. Yearly updates of training records for Certifying Staff shall be completed every January and will be submitted to the Quality Assurance manager. Unless permitted by the QA Manager, Administrative And Records Officer is authorized to sign and endorses the updated training records. The Technical Training shall maintain the records of each person who has undergone training and must contain the following information.

A. Course Particular

1. Type of Training 2. Training Entity and location 3. Duration and length of training 4. List of participants

B. Individual Record

Individual Record or summary of the result of each training course conducted or coordinated and completed must be prepared and disseminated to all concerned. A copy of the Individual Record must be retained in the Quality Assurance Division. A complete summary training record of individual technical personnel will be maintained and updated and considered the official record.


0

Rev. Date

March 2011

Page No.

1/1

Chapter

9


CHAPTER 10

MAINTENANCE & ENGINEERING DEPARTMENT

CAPABILITY LISTS

CONTROL NO : 10 Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

10


MAINTENANCE AND ENGINEERING DEPARTMENT

CAPABILITY LISTS:

POWERPLANT:

C. REPAIR AND OVERHAUL OF LYCOMING AND CONTINENTAL PISTON ENGINES UP TO 400 HORSEPOWER RATING

MODEL MANUFACTURER - 235, -290, -320, -340, -360, -540, -541, -480, -580 All Series

AVCO Lycoming

C75, C85, C90, C125, C145, E165, E185, E225, -200, -240, -300, -360, -470, -520, -550 All Series

Continental

A. REPAIR /OVERHAUL OF AIRCRAFT PROPELLER ** FOUR BLADED LIGHTWEIGHT TURBINE PROPELLER

MODEL MANUFACTURER HC-D4N-2A, HC-D4N-2AA, HC-D4N-2D, HC-D4N-2E, HC-D4N-2F, HC-D4N-2G, HC-E4A-2, HC-E4A-2A, HC-E4N-2, HC-D3F-7

HARTZELL PROPERLLER INC.

CONSTANT SPEED AND FEATHERING

MODEL MANUFACTURER HC-82-Series, HC-83-Series, HC-92-Series, HC-93-Series HC-A2-Series, HC-A3-Series, HC-B3-Series

HARTZELL PROPELLER INC.

COMPACT CONSTANT SPEED PROPELLER

MODEL MANUFACTURER HC-BHC-C2YF-A, -1A, -B CHC-DHC-C2YF-1B, HC-C2YK-A, -1A, -1B, HC-C2YL-1, 1B HC-C2YR-1B, HC-E2YR-1B, HC-F2YR-1, HC-C2YF, K, L-4, HC-C3YF, R, N-1

HC-E2YL-1B, HC-M2YR-1


CONTROL NO :10 Rev. No.

0

Rev. Date

March 2011

Page No.

1/15

Chapter

10


. MAINTENA NCE AND ENGINEERING DEPARTMENT

CAPABILITY LISTS:

COMPACT CONSTANT SPEED PROPELLER

MODEL MANUFACTURER BHC-J2YF-1BF (B)HC-12YF-(1, 4) ( )F (B) HC-L2YF-1, -2, -4 (E) PHC-L3YF-1R, (P) HC-C3YF-1R, HC-C3Y 9F,R,N) -4 ( )


THREE BLADED , CONSTANT SPEED AND FEATHERING

MODEL MANUFACTURER

HC-B3W30-2E, HC-B3P30-2E, HC-B3R30-2E, HA-B3P30-1B, HC-B3P30-1, HC-B3Z30-2E


** COMPACT NON-FEATHERING (-1) AND AEROBATIC (-4) PROPELLER

MODEL MANUFACTURER TWO BLADE

BHC-C2YF-1B (L) (F), CHC-C2YF-1-1B(L)(F) DHC-C2YF-1B(L)(F), HC-C2YF-1B(L)(F), HC-C2YK-1B (L)(F), HC-C2YL-1B(L)(F), HC-C2YR-1B(F), HC-E2YL-1B(L)(F) HC-E2YR-1(S)(F), HC-F2YL-1F, HC-F2YR-1(F), BHC-G2YF-1BF, BHC-12YF-1BF, HC-12YF-1BF, HC12YR-1BF, BHC-J2YF-1B(F), BHC-J2YF-1C, HC-M2YR-1BF,BHC-C2YF-4(B)(F), HC-C2YF-4 (B)(F) HC-C2YK-4 (A,B,C)(F), HC-C2YL-4(B)(F) HC,C2YR-4(A,B,C)(L)F, HC-C2YR-4E, HC-C2YR-4G, BHC-12YF-4(B)F, HC-12YF-4(B)F, BHC-L2YF-4(B)F, HC-L2YF-4(B)F

THREE BLADE HC-C3YF-1®(L)(F), PHC-C3YF-1MF, PHC-C3YF-1R(F), HC-C3YN-1(F), HC-C3YR-1A, HC-C3YR-1MF, HC-C3YR-1®(L)(F), HC-E3YR-1R(L)F, PHC-G3YF-1E, HC-G3YF-1RF, PHC-G3YF-1RF, HC-H3YF-1RF, PHC-H3YF-1RF, HC-13YR-1E, HC-I3YR-1RF, PHC-J3YF-1MF, HC-J3YF-1RF, PHC-J3YF-1RF, EHC-L3YF-1RF, PHC-L3YF-1RF , HC-L3YF-1RF, HC-M3YR-1RF,

HC-C3YF-4(B) F, PHC-C3YF-4(B)F,



0

Rev. Date

March 2011

Page No.

2/15

Chapter

10



CAPABILITY LISTS:

** COMPACT NON-FEATHERING (-1) AND AEROBATIC (-4) PROPELLER

MODEL MANUFACTURER

HC-C3YN-4(B)F, HC-C3YR-4A, HC-C3YR-4(B)F, HC-C3YR-4G

FOUR BLADE

HC-C4YF-1(E), HCF4YR-1


** COMPACT CONSTANT SPEED AND FEATHERING PROPELLER

MODEL MANUFACTURER

TWO BLADE BHC-C2YF-2 ( ), CHC-C2YF-2 ( ), DHC-C2YF-2 ( ), HC-C2YF-2 ( ), HC-C2YK-2 ( ), HC-C2YL-2 ( ), HC-E2YK-2 ( ), HC-E2YL-2 ( ), HC-E2YR-2 ( ), HC-F2YL-2 ( ), HC-F2YR-2 ( ), HC-I2YF-2 ( ), BHC-J2YF-2 ( ), BHC-L2YF-2 ( ), HC-L2YF-2 ( ), HC-M2YL-2 ( ), HC-M2YR-2 ( )

THREE BLADE

EHC-C3YF-2 ( ), HC-C3YF-2 ( ), PHC-C3YF-2 ( ), HC-C3YN-2 ( ), HC-C3YR-2 ( ), HC-E3YR-2 ( ), HC-F3YR-2 ( ), EHC-G3YF-2 ( ), HC-G3YF-2 ( ), PHC-G3YF- 2 ( ), HC-H3YF-2( ), PHC-H3YF-2 ( ), HC-H3YN-2 ( ), HC-I3YF-2 ( ), PHC-I3YF-2 ( ), HC-I3YR-2 ( ), PHC-J3YF-2 ( )

FOUR BLADE HC-C4YF-2 ( ), HC-C4YN-2 ( ), HC-C4YR-2 ( ), HC-F4YR-2 ( )



0

Rev. Date

March 2011

Page No.

3/15

Chapter

10



CAPABILITY LISTS:

** STEEL HUB TURBINE PROPELLER

MODEL MANUFACTURER

THREE BLADE HC-A3VF-7, HC-A3VF-7A, HC-A3VF-7B, HC-A3MVF-7, HC-A3MVF-7A, HC-A3MVF-7B, HC-B3MN-3, HC-B3TN-2, HC-B3TN-2B, HC-B3TN-3, HC-B3TN-3A, HC-B3TN-3AE, HC-B3TN-3(Y), HC-B3TN-3B, HC-B3TN-3BY, HC-B3TN-3C, HC-B3TN-3D, HC-B3TN-3DL, HC-B3TN-3DY, HC-B3TN-3E, HC-B3TN-3F, HC-B3TN-3G, HC-B3TN-3H, HC-B3TN-3K, HC-B3TN-3M, HC-B3TN-3N, HC-B3TN-3P, HC-B3TN-3S, HC-B3TN-3UL, HC-B3TN-3Z, HC-B3TN-5, HC-B3TN-5C, HC-B3TN-5CL, HC-B3TN-5D, HC-B3TN-5DL, HC-B3TN-5FL, HC-B3TN-5G, HC-B3TN-5K, HC-B3TN-5M, HC-B3TN-5ML, HC-B3TN-5N, HC-B3TN-5NL, HC-B3TN-5P, HC-B3TN-5SL, HC-B3TN-5U, HC-B3TN-5W, HC-B3TF-7, HC-B3TF-7A, HC-B3TF-B, HC-B3TF-7C HC-B3TF-7


** STEEL HUB TURBINE PROPELLER

MODEL MANUFACTURER

FOUR BLADE

HC-B4MP-3, HC-B4MP-3A, HC-B4MP-3B, HC-B4MP-3C, HC-B4TN-3, HC-B4TN-3A, HC-B4TN-3B, HC-B4TN-3C, HC-B4MN-5AL, HC-B4MN-5L, HC-B4TN-5, HC-B4TN-5A, HC-B4TN-5AL, HC-B4TN-5C, HC-B4TN-5CL, HC-B4TN-5DL, HC-B4TN-5EL,, HC-B4TN-5F, HC-B4TN-5FL, HC-B4TN-5GL, HC-B4TN-5HL. HC-B4TN-5JL, HC-B4TN-5KL, HC-B4TN-5ML, HC-B4TN-5NL,

HARTZELL PROPELLER INC


0

Rev. Date

March 2011

Page No.

4/15

Chapter

10



CAPABILITY LISTS:

** FULL FEATHERING CONSTANT SPEED PROPELLER

MODEL MANUFACTURER

2AF31C Series, 2AF34C Series, 2AF36C Series, 3AF32C Series, 3AF34C Series -200,-300,-400,-500 Series (threadless)

MC CAULEY.

** FIXED PITCH PROPELLER

MODEL MANUFACTURER

1A90-CF, CH, 1A100-ACM, MCM, 1A101-DCM, GCM, HCM, 1A102-0CM, 1A105-BCM, SCM, SLM, 1A135-BRM, JCM, KCM, RM, 1A170-CFA, DF, DM, EFA, GM, L, LL, 1A175-ATM, DM, FC, GM, GMA, SFA, SFC, 1A200-AOM, DFA, FA, FM, 1B90-CM- ECM, FCM, LCM, 1B175-MFC, 1B200-HM, 1B235-BFAM\, DFC, 1C235LFA/7570 Sensinich Propeller (Fixed Pitch) all series /Model 1C90-ALM-CLM, DLM, LF, LM, 1C160- CTM, EGM, 1C172-ACM, BTM, EM, MDM, MFA, MGM, MTM, SBTM, TM 1C200-FC, 1D200-OM, IP235-AFA, PFA

MC CAULEY SENSENICH


01

Rev. Date

23 July ‘14

Page No.

5/15

Chapter

10



CAPABILITY LISTS: ** CONSTANT SPEED PROPELLER

MODEL MANUFACTURER 2D34C-8, 2D34C9, B2D34-C11, 2D36C14, 2D36C14A, 2D36C14B, B2D34C16, 2A31C21, 2A34C22, 2A36C23, 2D36C28, 2D35C28A, 2A36C29, 2A36C29A, BD2A36C31, BD2A36C31A, C2A36C32, C2A36C32A, D2A36C33, D2A36C34, D2A36C45, D2A34C49, 2A34C50, B2D34C53, 2D34C53, D2A34C58, F2A34C58, E2A34C64, 2A34C66, D2A34C67, E2A34C70, E2A34C73, 3A32C76, D3A32C77, D2A34C78, D3A32C79, 2A36C82, D3A32C88, D3A32C90, D2006/90M, D2101/78KM CHg A, D2101/78KM CHg B. C, D2101/78KM CHg D, D-2286/80MM CHg C, D-2286/80MM CHg D, D-2341/90M CHg A D-2341/90M CHg B, D-2859/84B, D-2970/84S, D-3108/90A, D-3129/74E, D3223/90AT, D-3442/84AF, D-3450/76C, D-3542/82NK, D-3546/90AT, D3582/82NB, D-3591/84B, D-3663/82NC, D-3769/78FB, D-3784/84HF, D-3895/84HF/ D-4027-84JF, D-4296/78FBM, D-4182/84SF, A-1934, A-2961, B-3531, C-2232, C2343, C2414, C2446, C-2715, C-2795, C-2835, C-2959, C-3389, C-4195, C-4197, D-4199, C-4201, C-420, C-4204, D-4211, D-4216,, D4329, C-4356, C-4363, C-3103, C-3105, C-3128, C-3453, D-3522, D-3541, D3561, D3581, D-3768, C-3894, D3944, D3946, D-3948, C-3958, C-3960, C-3978, D-3980, C-3990, D-2137, D-2771, D-2771-1, D-2809, D-2822, D-2845, D-3290, D-3396, D-3584, D-3669, D-3683, D-3766, D-3867

MC CAULEY.

** VARIABLE PITCH PROPELLER

MODEL MANUFACTURER 33LF-337, 33LF-33B HAMILTON


0

Rev. Date

March 2011

Page No.

6/15

Chapter

10



CAPABILITY LISTS:

C. REPAIR /OVERHAUL OF AIRCRAFT PROPELLER GOVERNOR (PISTON) MODEL MANUFACTURER A-1, A-1B, A-1C, A-1-1, A-11B, B-0, B-1, B-2, B-3, B-3-1, B-3-2, B-4, B-3-4, B-4-1, B-4-2, B-4-3, B-4-5L, B-4-5R, B-4-6, B-4-7, B-4-8, B-4-9, B-4-10, B-4-11, B-5, B-8, B-8-1, C-1, C-2, C-3, C-3-1, C-4, C-4-1, D-1, D-1-1, D-1-2, D-1-3, D-1-4, D-1-5, D-1-7, D-1-8, D-1-9, E-1, E-2, E-3, E-3L, E-3-1, E-3-2, F-2-9A, F-3, F-3-2, F-4,F-4-1, F-4-1A, F-4-1B, F-4-1C, F-4-1D, F-4-2, F-4-3, F-4-3A, F-4-4, F-4-4A, F-4-5, F-4-5A, F-4-6A, F-4-6B, F-4-7A, F-4-8, F-4-10, F-4-11, F-4-11A, F-4-11C, F-4-16, F-4-18, F-4-20, F-4-21, F-4-23, F-6-3, F-6-3A, F-6-3AL, F-6-3S, F-6-4, F-6-4S, F-6-5, F-6-5A, F-6-5AB, F-6-5S, F-6-6, F-6-6A, F-6-6S, F-6-7, F-6-7A, F-6-7S, F-6-8, F-6-8A, F-6-8S, F-6-9, F-6-14A, F-6-14S, F-6-15A, F-6-16A, F-6-16S, F-6-17A, F-6-18A, F-618L, F-6-19, F-6-19, F-6-20, F-6-22, F-6-24, F-6-24L, F-6-25, F-6-26, F-6-27, F-6-31, F-6-33, F-6-34, F-6-35, F-6-36, F-6-37, F-6-38, F-6-39, F-6-40, F-6-43, F-6-44, F-6-46, F-6-47, F-8-3A, F-8-11A, F-8-24, F-8-24L, F-8-28, F-8-29, F-8-32, F-8-33, F-8-35, F-8-38, F-8-39, F-8-43, F-8-44, F-8-47, H-1, H-1-L, H-1-1, H-1-2.



0

Rev. Date

March 2011

Page No.

7/15

Chapter

10



CAPABILITY LISTS

** PISTON ENGINE CONSTANT SPEED PROPELLER GOVERNOR

MODEL MANUFACTURER 210055-AM1, 210105-1 AR1, 210110-G2, 210190-R1, 210285-R, B210310-N1, 210335-H, E210340-N, E210345-M, 210360-H, 210385-J, 210400-K, B210403-F, 210409-G, 210412-J, 210417-J, 210417-G, 210428-F, A210436-M2, D210439-T , B210444-F, B210446-H1, C210452-T, K210452-T , 210456-P1, 210467-C, C210472-H1B210473-N1, B210490-F1, 210497-R2, A210504-N2, A210512-F1, 210516-L2, B210529-V, 210456-M3, 210562-C, B210572-D, A210582-D, 210586-C2, B210595-D2, A210597-N1, R210652-J, C210655-V, B210659-M, G210659-M, 210665-M1, 210669-K, 210667-F, B210680-AB, 210681-AB, E210681-AB, 210682-G, 210060-AL2, B210105-AR1, 210115-AB3, 210240-Y1, 210290-T, C210310-N1, 210340-N, 210345-M, J210345-M2, A210360-H, A210385-H, A210400-K2, C210403-F, B210409-G, 210413-H1, 210419-G, 210433-T1, A210438-M1, 210443-F1, C210444-F, C210446-H, D210452-T1, L210452-T3, 210458-F, 210468-C1, D210472-H1, 210481-D, C210490-F, 210498-R1, 210505-S1, 210513-J1, 210521-A, C210529-V, 210550-B1, R210571-B, C210572-D1, B210582-D, 210587-E3, 210596-L, A210601-C, 210653-C, 210657-C, C210659-M, 210660-U, 210666-M, B210669-H1, L210679-D1, C210680-AB, A210681-AB, F210681-AB, 210685-V, 210080-AK1, C210105-AR1, 210120-AA1, 210245-P, 210305-V, A210315-R, B210340-N, B210345-M3, 210350-K, 210365-K1, 210390-W1, 210401-M1, 210404-V, 210410-H3, 210414-T2, A210419-G, 210434-S, B210438-M3, A210443-D2, F210444-F, 210452-T, F210452-T, M210452-T, 210460-G, 210472-H1, E210472-H1, 210484-NW2, E210490-F2, A210499-N1, 210506-N2, A210513-J1, A210521-A, D210529-V, A210550-B1, R210571-B, L210573-C1, 210-573-B, 210594-C1, B210596-L, 210609-C, 210655-V, 210658-D, D210659-M, 210662-M, A210666-M1, 210674-H, R210679-D1, D210680-AB, B210681-AB, G210681-AB, 210686-T, 210085-AG1, H210105-AR1, 210155-T1, 210275-E1, A210305-V, 210330-S, C210340-N,

WOODWARD


0

Rev. Date

March 2011

Page No.

8/15

Chapter

10



CAPABILITY LISTS

** PISTON ENGINE CONSTANT SPEED PROPELLER GOVERNOR

MODEL MANUFACTURER C210345-M, A210355-AB2, A210375-K, A210390-W1, 210402-L2, 210405-F, B210410-H2, 210415-G1, B210419-G, B210434-S, 210439-T, 210444-F, A210446-H1, B210452-T, H210452-T , U210452-T1, 210464-E, B210472-H1, A210473-N1, A210490-F1, 210493-J, 210504-N1, 210512-F, 210515-L, A210529-V, 210533-J2, 210556-P1, A210572-D, 210582-D, 210585-D, A210595-D1, 210597-N1, L210652-J, B210,655-V, A210659-M, F210659-M, 210664-L1, 210668-R, 210676-F, A210680-AB, F210680-AB, D210681-AB, J210681-AB1, 210688-P, B210688-P, B210689-J, 210692-K, A210693-H, A210703-E, R210707-H1, C210710-V, 210712-K, D210713-J, 210716-F, B210719-E, 210722-M1, 210731-D, 210758-F, A210802-F, 210907-B, 210910-D, R210914-C1, R210924-C1, C210688-P, D210689-J, A210692-K, 210700-N, 210704-F, 210709-F, D210710-V, 210713-J, E210713-J, 210717-K, C210719-E, 210726-F, 210732-B1, D210760-D, L210880-B, L210908-B1, 210911-C, A210921-E, D210688-P, F210689-J, B210692-K, A210700-N, 210706-C, A210709-F, E210710-V, A210713-J, 210714-M, 210718-H, D210719-E, 210727-C, 210733-C1, E210760-D, R210880-B, R210908-B1, L210913-B2, B210921-E, 210689-J, 210690-K, C210692-K, 210702-L, A210706-C, A210710-V, F210710-V, B210713-J, 210715-D1, 210719-E, 210721-N1, 210728-G, 210752-D1, A210761-F. 210903-H, L210909-B, R210913-B2, 210923-C, A210689-J, 210691-H, 210693-H, 210703-E, 210707-H1, B210710-V, 210711-U, C210713-J, B210715-D1, A210719-E, A210721-N1, A210728-G, 210753-F, B210761-F, 210905-B, R210909-B, L210914-C1, L210924-C1.

WOODWARD


0

Rev. Date

March 2011

Page No.

9/15

Chapter

10



CAPABILITY LISTS

D. REPAIR/OVERHAUL OF MAIN AND NOSE LANDING GEAR

(BN-ISLANDER AND CESSNA)

** NOSE UNDER CARRIAGE LEG

MODEL MANUFACTURER AIR 48280/1, AIR 48280/2, AIR 48280/3, AIR 48280/4, AIR 48280/5, AIR 48280/6, AIR 48280/7, AIR 48282, AIR 46202/1, AIR 46202/2, AIR 46202/3, AIR 46202/4.

AP PRECISION HYDRAULICS

** MAIN UNDER CARRIAGE LEG

MODEL MANUFACTURER AIR 48934/1, AIR 48934/2, AIR 48934/3, AIR 48934/4 AIR 48934/5, AIR 48934/6, AIR 48934/7, AIR 48934/8 AIR 48934/9, AIR 48934/10, AIR 48934/11, AIR 46200/1, AIR 46200/2, AIR 46200/3, AIR 46200/4, AIR 46200/5, AIR 46200/6, AIR 48958/1, AIR 48958/2, AIR 48958/3, AIR 48958/4, AIR 48958/5, AIR 48958/6, AIR 48958/7, AIR 48958/8, AIR 48958/9, AIR 48958/10, AIR 83002/1, AIR 83002/2,

AP PRECISION HYDRAULICS

** NOSE UNDER CARRIAGE LEG

MODEL MANUFACTURER 3501H SERIES, 3811H SERIES. FAIREY

** MAIN UNDER CARRIAGE LEG

MODEL MANUFACTURER 3499H SERIES, 3507 H1

FAIREY


0

Rev. Date

March 2011

Page No.

10/15

Chapter

10



CAPABILITY LISTS

COMPONENTS/ACCESSORIES CAPABILITY LISTS:

A. Fuel Control Unit

Fuel Pump

MODEL PART NUMBER MANUFACTURER Romec Pump RG 17980 ROMEC

Fuel Injector

MODEL PART NUMBER MANUFACTURER RSA10ED1 2524273/2524298/2524366/2524420/

2524422/2549038/2524733/2524811/ 2524846/2524859/2524880/2524477/ 2524491/2524492/2524500/2524534/ 2524556/2524582/2524601/2524693/ 2524709

Precision Airmotive

Fuel Nozzle

MODEL PART NUMBER MANUFACTURER Precision 2524107/2524864/2524369//

252370/2524703/2524865/ 2524866/2524881/2524917/ 2524923/2524925/2524926

Precision Airmotive

Fuel Manifold Valve/Fuel Flow Divider

MODEL PART NUMBER MANUFACTURER Precision 2524231-2/252610-

2/2576526-1/2576532-1/2576552-1/257556-1/2576564-1/257662-1/2576624-1

Precision Airmotive


0

Rev. Date

March 2011

Page No.

11/15

Chapter

10



CAPABILITY LISTS

MAGNETO, STARTER AND ALTERNATOR

MODEL PART NUMB ER MANUFACTURER

All series S-1200, S-200, S-20 Bendix King

All brand & model MHB, MHJ, MHZ, MZ Prestolite

All brand & model ALT, ALX, ALV, ALY & ALZ

Prestolite

C. Hydraulic Bench Check Flap Actuator, Flap Selector Valve, Steering Actuator SPECIALIZED SERVICES:

AIRCRAFT NON-DESTRUCTIVE TESTING

o Visual Inspection o Liquid Penetrant Inspection o Magnetic Particle Inspection o Eddy Current Inspection


01

Rev. Date

23 Mar 12

Page No.

12/15

Chapter

10



CAPABILITY LISTS

A PRECISION MACHINING o Contour machined on computer numerically lathe for precision dimensional control using

Boehringer Lathe, Run master Lathe, Bridgeport Milling, Tos Hostivar Cylindrical Grinder and Henu hauser Jig Borer Machine

o Pilot diameter restored by machining the requirement as per standard acceptable procedure o Mounting Flange machining as required to enhance the CEB requirement

B CALIBRATION

Traceable to National Standards

o Pressure Gauges - 0-5000 PSI Wet Type o Torque Wrenches- range 0-200 ft-lb / 0-200 in-lb o Temperature Gauges o Vernier Calipers o Micrometers o Dual Indicator o Height indicator

C WELDING

o Electric Arc o Tig Welding (deferred due to non availability of technician)

D BATTERY CHARGING

o Lead Acid o Nickel Cadium

D. AIRCRAFT WEIGHING

Limited up to aircraft with 150,000 lbs empty weight capacity

ALL WORKS SHALL BE ACCOMPLISHED IN ACCORDANCE WITH CURRENT

MANUFACTURERS MANUAL.


01

Rev. Date

08 Aug. 13

Page No.

13/15

Chapter

10



CAPABILITY LISTS

F FLIGHT AND ENGINE INSTRUMENTS BENCH CHECK/CAL IBRATION

o Pitot static system testing (up to 400 knots airspeed/35,000 ft altitude) o Altimeters (up to 35,000 ft) o Airspeed indicators (up to 800 mph) o Vertical speed indicators o Voltmeters o Ammeters o RPM indicators o Temperature gauges o Fuel content indicators o Fuel pressure gauges o Oil pressure gauges

G AIRFRAME INSPECTION AND REPAIR H AIRCRAFT STRUCTURAL COMPONENT ASSEMBLY

I . FIB ERGLASS FABRICATION/LAMINATION REPAIR/AIRFRAME

REPAIR

J AIRCRAFT IRAN AND PROGRESSIVE LINE MAINTENANCE SE RVICES

o BN-Islander (BN-2A and BN-2B) o Cessna 150, 152, 172, 206 , 206T and 421 series o Piper Seneca, Cherokee, Tomahawk, Aztec Series o Socata TB9C Tampico

K MODIFICATION OF AIRCRAFT INTERIOR H. OXYGEN BOTTLE SERVICING (DE-CONTAMINATION AND REFILLING)


02

Rev. Date

23 July’14

Page No.

14/15

Chapter

10



CAPABILITY LISTS

M HYDRAULIC SYSTEM CHECK

o Landing gears extension and retraction test o Hydraulic actuators leak and functional testing

N Pitot Static System Test / ATC Transponder System Check, Compass Swing Test,

Installation /Functional Operational check of Emergency Locator Transmitter of the following aircraft model:

o BN-Islander aircraft all model series o Cessna aircraft all model series o Piper aircraft all model series o Beechcraft aircraft all model series o Socata TB9C Tampico o All other type of light aircraft and helicopter

]


02

Rev. Date

23 July’14

Page No.

15/15

Chapter

10


CHAPTER 11

APPENDICES

CONTROL NO: APPENDICES Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

11


INDIVIDUAL RECORD

CONTROL NO: 11-A Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

11


FORMS

CONTROL NO: 11-B Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

11


MANPOWER RESOURCES

CONTROL NO: 11-C Rev. No.

0

Rev. Date

March 2011

Page No.

Chapter

11


11-C MANPOWER RESOURCES

PERSONNEL STRENGTH

23 July 2014

OFFICE OF THE PRESIDENT 1. Cueto, Conrado C. Acting-President/Accountable Manager 2. Cayme, Olivia Marie Contractual as per Job Order TREASURY DEPARTMENT

1. Broas, Rolando P 2. Suba, Antonio P ACCOUNTING DEPARTMENT

1. Cabangangan, Josefa P 2. Dizon, Gloria P 3. Duque, Nely P 4 Cruz, Rosemarie P

ADMINISTRATIVE SERVICES DEPARTMENT

Personnel Division 1. Almonia, Adela P 2. Castañeda, Phyllis P 3. Rosario, Ranier P 4. Cruz, Perry Jannsen Contractual as per Job Order


03

Rev. Date

23 July’14

Page No.

1/4

Chapter

11


11-C MANPOWER RESOURCES GENERAL SERVICES DIVISION

1. Andong, Isidro P 2. Banta, Danilo P 3. Costelo, Valerio P 4. Dubria, Isagani Contractual as per Job Order 5. Pepito, Eddie Contractual as per Job Order 6. Seron, Bibiano Contractual as per Job Order 7. Villariza, Ma. Theresa Contractual as per Job Order 8. Monteflor, Rocel Contractual as per Job Order 9. Imperial, Sanny Contractual as per Job Order 10. Villagorda, Leonardo Contractual as per Job Order 11. Villagorda, Ricardo Contractual as per Job Order LOGISTICS DEPARTMENT

1. Acero, Thelma P 2. Ferrer, Fortunato P 3. Matias, Redencion P 4. Tapac, Loreta P 5. Pareja, Vivian Contractual as per Job Order 6 Calabria, Drusella Contractual as per Job Order 7 Aguinaldo, Chona P

QUALITY ASSURANCE DIVISION 1. Miralpes, Nelson P 2. Magbanua, Ricardo P 3. Fahigal, Flordelino P


03

Rev. Date

23 July 14

Page No.

2/4

Chapter

11


11-C MANPOWER RESOURCES OPERATIONS GROUP

MARKETING DEPARTMENT

1. Bersamira, Annie P 2. Dimaano, Maxilinda P 3. Solomon, Jonathan P 4. Felipe, Ryan Contractual as per Job Order 5. Saluta, Kristina Contractual as per Job Order MAINTENANCE & ENGINEERING DEPARTMENT 1. Alarcon, Conrado P 2. Aguila, Richard P 3. Amion, Agapito P 4. Willie A. Ilustre T 5. Cañeso, Winifredo P 6. Cruz, Magie R. P 7. De Galicia, Reynante P 8. Delgado, Rodel P 9. Domingo, Gumersindo P 10. Ebasco, Francis Erick P 11. Eclarinal, Elmer P 12. Galang, Edgardo P 13. Hicban, Teodorico P 14. Quitain, Christian Joseph P 15. Rago, Mario P 16. Saria, Ramon P 17. Sisik, Roger P 18. Villafuerte, Erdi P 19. Oliquiano, Angelina Contractual as per Job Order 20 Espinosa, Pete Aldhecs P


03

Rev. Date

23 July 14

Page No.

3/4

Chapter

11


11-C MANPOWER RESOURCES INTERNAL AUDIT DEPARTMENT

1. Linsag, Mark Timothy P C O A 1 Arnesto, Rebecca 2. Fagara, Yolanda 3. Patalinjug, Ramon 4. de Villa, Zenaida

EMPLOYEE TURNOVER AS OF 23 JULY 2014

GRAND TOTAL …………………………………………… 63


03

Rev. Date

23 July’14

Page No.

4/4

Chapter

11

NON-DESTRUCTIVE TESTING 6.18.3.2 EDDY CURRENT METHODS · Date 2 nd Issue : 07 March 2011 CAAP Approved Maintenance Organization No. 01-76 Rev. NON-DESTRUCTIVE TESTING 6.18.3.2 EDDY

Documents