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NONDESTRUCTIVE INSPECTION
(NDI)
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INTRODUCTION
The effectiveness of any particular method of NDI
depends upon the skill, experience, and training of
the person(s) performing the inspection process.
The product manufacturer or the Federal Aviation
Administration (FAA) generally especifies the
particular NDI method and procedure to be used in
inspection.
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TRAINING, QUALIFICATION, AND
CERTIFICATION.
The success of any NDI method and procedure
depends upon the knowledge, skill, and experience
of the NDI personnel involved.
The person should be familiar with the test method,
know the potential types of discontinuities peculiarto the material, and be familiar with their effect on
the structural integrity of the part.
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NDT LEVELS.
Level I Special (Optional). Level I Special is the
lowest qualification level and is task specific.
Personnel may be qualified to this level to perform
a specific task on a particular component.
An example of this level is the Eddy Current
Inspection of aircraft wheels.
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LEVEL I. LEVEL I SHOULDBEFORASPECIFIC
METHOD.
To be qualified for Level I, an individual should have
the skills and knowledge to perform specific tests,
specific calibrations, and specific interpretations
and evaluations for acceptance or rejection.
1) be knowledgeable of any necessary preparation
of parts before or after inspection,
2) be able to follow procedures pertinent to the
techniques for which he/she is qualified,
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3) receive the necessary guidance or supervision
from a qualified Level H, Level M, or other
designated individual, and
4) meet the training and experience guidelines in
Table 1.
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LEVEL II.
Should have the skills and knowledge to set up and
calibrate equipment, conduct tests, and to interpret,
evaluate, and document results in accordance with
procedures in all techniques in the methods used
by his or her organization.
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He or she should be able to organize and document NDIresults and should be familiar with the codes, standards,and other regulatory documents which control themethod used by the organization.
(1) AIA-NAS410, Aerospace Industries Association,National Aerospace Standard, NAS Certification &Qualification of Nondestructive Test Personnel
(2) ATA Specification 105, Air Transport Association,Guidelines for Training and Qualifying Personnel inNondestructive Testing Methods
(3) PCN/GEN/92, General Requirements for the Certificationof Personnel Engaged in Nondestructive Testing at Levels 1,2, and 3. (PCN Certification Services, British Institute of NDI, 1Spencer Parade, Northampton NN1 5AA, UK)
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LEVEL III.
(a) Have graduated from a minimum four-year
college or university curriculum degree in
engineering or a related science, plus one year
minimum experience in NDI testing assignment
comparable to that of an NDI Level II in the applicableNDI method(s);
(b) Have completed two years of engineering or
related science study at a university, college, or
technical school, plus two years experience in
assignments at least comparable to that for NDI Level II
in the applicable NDI method(s);
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(c) Have four years experience in an
assignment at least comparable to that of an
NDI Level II in the applicable NDI method(s).
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EXAMINATION.
(1) Physical Examination.
(a) Vision. the individual can read Snellen equivalent
of 20/20 (Jaeger #1).
(b) Color Perception. Distinguish anddifferentiate
between colors necessary for the inspection
method
(c) Physical Requirements. The physical
requirements established by the organization as a
condition of employment will normally suffice.
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(2) General Skills Examination.
(a) The general examination for all skill levelsshould be a closed-book examination consisting
of questions that cover the basic inspection/test
principles
(b)A minimum of 40 questions should be used for the
general examination and
(c) The examination should also cover thespecifications and/or standards used by the
organization in its nondestructive inspection
procedures.
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(3) Practical Examination (Classroom). should
satisfactorily demonstrate that he/she is familiar
with and canoperate the necessary test equipment
and interpret the resultant information to the degree
required by the Level III instructor.
(4) Practical Examination (OJT Shop). The hours
of OJT training are defined inthe experience section
of Table 1.
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(5) FAA Certification. Upon satisfactory
completion of the required physical and general
skills examinations; the classroom and OJT shop
practical examinations,
REQUALIFICATION/RECURRENT TRAINING.
Requalification examinations should consist of
a demonstration of proficiency in the procedure for
which the applicant is being examined.
Requalification should occur, at a minimum, every
three years.
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SELECTING THE NDI METHOD.
The NDI method and procedure to be used forany
specific part or component will generally bespecified in the aircraft or component
manufacturers maintenance or overhaul manuals,
SSIDs, SBs, or in ADs.
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b. Other Factors. Other factors affecting the
inspection are:
(1) The critical nature of the component;
(2) The material, size, shape, and weight of the part;
(3) The type of defect sought;
(4) Maximum acceptable defect limits in size anddistribution;
(5) Possible locations and orientations of defects
(6) Part accessibility or portability; and
(7) The number of parts to be inspected.
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c. Material Safety Data Sheets (MSDS). The
various materials used in NDI may contain
chemicals, that if improperly used, can be
hazardous to the health and safety of operators and
the safety of the environment, aircraft, and engines.
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e. Advantages and Disadvantages. Table
provides a list of the advantages and
disadvantages of common NDI methods.
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VISUAL INSPECTION
Visual inspection is the oldest and most common
form of NDI for aircraft. Approximately 80 percent of
all NDI procedures are accomplished by the direct
visual methods.
Visual inspection provides a means of detecting
and examining a wide variety of component and
material surface discontinuities, such as cracks,
corrosion, contamination, surface finish, weld joints,solder connections, and adhesive disbonds.
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SIMPLE VISUAL INSPECTION
Visual inspection aids such as a powerful flashlight,
a mirror with a ball joint, and a 2 to 10 power
magnifying glass are essential in the inspection
process.
a. Flashlights. Flashlights used for aircraft
inspection should be suitable for industrial use.
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b. Inspection Mirrors.
An inspection mirror is
used to view an area
that is not in the normalline of sight.
c. Simple Magnifiers. A
single converging lens,
the simplest form of a
microscope, is often
referred to as a simple
magnifier.
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BORESCOPES.
These instruments are long, tubular, precision
optical instruments with built-in illumination,
designed to allow remote visual inspection of
internal surfaces or otherwise inaccessible areas.
The tube, which can be rigid or flexible with a wide
variety of lengths and diameters, provides the
necessary optical connection between the viewing
end and an objective lens at the distant, or distal tipof the borescope.
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VISUAL INSPECTION PROCEDURES.
Preliminary Inspection.
Corrosion Treatment.
Lighting.
Personal Comfort. Noise.
Inspection Area Access.
Precleaning.
Inspection.
Recordkeeping.
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