ANALYSIS AND INNOVATION FOR
PENETRANT TESTING FOR AIRPLANE Gilar Bagaskoro Buono
PARTS 1606863466
INTRODUCTION
Whether the helicopter or the aerotransport, NDT methods are
used in the development phase, manufacture phase, use phase,
and maintenance phase.
Especially penetrant testing is the efficient measure.
WHERE?
We confirm the parts which do the penetrant testing according to
the load in the development phase;
Have penetrant testing after the working procedure which produce
the defects in manufacture phase;
Have penetrant testing for the area which use the big load in use
phase.
We must ensure the validity of penetrant testing in every
phase.
The arrangement of penetrant procedure ,surface prepare of
machine parts ,protection of on-working parts, these are all
the problems in the practice working.
We analysis and innovate these problems, halve the
experience with the other NDT technicians.
RESEARCH AND DEVELOPMENT PHASE
RESEARCH AND DEVELOPMENT PHASE
In the development phase of the airplane, now the company
usually adopt the joint work form in parallel, in this journal the
writer had the opportunity to participate the joint work in parallel
of several models, and have some ideas about penetration testing
in the development phase
DETERMINE THE NEED FOR TESTING PART
By comparison, there are differences in penetrant testing between the
number and variety of parts in each model, as shown in table 1.
SUGGESTIONS AS THE POINT OF PENETRATION
TECHNOLOGY PROFESSIONALS
1. At first the design personnel shall determine the importance of the
parts according to the load, if the critical value of load is determined
by testing for the important parts, and we should prescribe the value
load if it need have penetrant testing
2. To determine which mechanical operation are the parts used during
their manufacturing process, and which defects can produce after
these operations, and determine whether the parts need have
penetrant testing according to affect the future use.
THE MANUFACTURE PHASE
PENETRATION TESTING PROCESS ARRANGEMENT
IN PARTS PROCESS CARD
Process arrangements have a rule from the perspective of penetrant
testing:
“Perform penetrant inspection after all operations that could expose
or cause surface connected discontinuities, such operations include but
be not limited to: grinding,welding straightening,machining,spin
forming,heat treating etc.”
CIRCS TO NEED HAVE PENETRANT TESTING IN
MACHINING PROCESS
1. Process in check - the inspection after the completion of a certain
process, but not all process and the process may produce
discontinuity, so have penetrant inspection to ensure the quality
of parts before put into next working procedure in good
condition.
2. Final inspection - refers to the inspection after the all process,
the process may produce discontinuity or appear the
discontinuity which can affect the quality of parts.
SURFACE PREPARATION PROCESS ARRANGEMENT
BEFORE PENETRANT TESTING
We must form a complete set of surface cleaning process before
Penetrant testing, because the parts before penetration test,
requiring all surface is clean, dry, no dust pollution, paint,
coating and other hamper penetrant infiltration discontinuity of
the material.
SURFACE PREPARATION PROCESS ARRANGEMENT
BEFORE PENETRANT TESTING
Material cleaning process arrangement is different for Different
models.
Eurocopter compiled the cleaning docunment EI070-09-039 for
pentrant testing, all kinds of surface condition of parts is
prescribed the different cleaning steps, which is of great
significance, but some content need to update, such as
trichloroethylene belongs to international environmental banned
drugs, environmentally friendly cleaning agents should be used
instead.
PENETRANT TESTING OF THE FINISHED
COMPONENTS
The again machining surface
on the fixed ring components
of the writer factory
production need do penetrant
testing according to the
drawing requirements.
PENETRANT TESTING OF THE FINISHED
COMPONENTS
1. Detection area is the area within the dotted line as shown in figure 1,
there are 18 only ф 5 mm diameter threaded holes.
2. The need to protect is as shown in the combination of plane and 4
incisions, and 18 threaded holes in accordance with the design
requirements.
3. A local test for the critical part, cannot use the spray can of color to
detect, although spray cans be convenient operation, but the sensitivity
can’t meet the requirements.
4. Locally applied, use level 3 or higher sensitivity of the fluorescent
penetrant which remove by the solvent.
PENETRANT TESTING OF THE FINISHED
COMPONENTS
after much trial and error, to achieve a satisfactory detection requirements,
the writer adopt the following protection methods:
Dip the viscous oil with toothpicks to seal interface and incision.
The oil has no effect on the subsequent use of components
The production of special plastic pin block 18 threaded hole, as
shown in figure 2.
PENETRANT TESTING OF THE FINISHED
COMPONENTS
Make the square bottom of the pin dip in with oil, then screw into
the threaded hole, then use cotton cloth dipped in the solvent, to
wipe clean the edge of the joint surface between the pin and
screw thread.
Its needed so penetrant cannot penetrate into surface, also does
not affect to the edge detection, the interference of penetrant
which return shows almost 0, don't worry after the post-cleaning
problems.
The method principle of practicality is very strong.
ETCHING OF THE PARTS BEFORE PENETRANT
TESTING
it is controversially what parts need to etch?
Etched in the practical work, aluminum alloy parts is very common,
because aluminium alloy is a soft metal, easier to plug in the
processing course. For parts finished by nc machining are very good,
needn’t be polished, so needn’t be etched before penetrant testing.
The burrs must be grinded if these are burrs on the ordinary
processing surface, generally use the 300-320 emery cloth to make
rough grinding, then use the 500 sandpaper to make fine grinding .
The repeated grinding area must be carried out etching to ensure the
effectiveness of the penetrant testing. [3]
POST-CLEANING AFTER PENETRANT TESTING
there are three conditions for the cleaning:
1. Only use compressed air to remove surface residue, this method
can only remove about, can't completely.
2. Wash by the water, and then thoroughly dry parts.
3. Dry after water washing, clean with trichloroethylene again
THE USE PHASE
SURFACE PREPARATION PRIOR TO PENETRATION
TESTING FOR PARTS IN SERVICE
Aircraft in use process, the requirement for the part of the
problem area do penetrant detection, the surface of the used
parts will be a serious pollution, oxide and other interfere.
If the parts can be disassembly, we can adopt the method of
acid pickling; if you can't be disassembly, we can use sand
paper burnish the part or inspected area, then etched away a
thin layer, and then we can proceed penetrant testing .
THE PROTECTION OF LOCAL DETECTION FOR
PARTS
The parts which can’t be disassemble from the airplane, need
protect adjacent areas and combination surface before penetrant
testing, once the penetrant material enters the combination surface,
it will be very difficult to clean.
Usually we adopt polyethylene film and protection cover to
protect, and apply penetrant using the brush. But in fact the
protection effect of adhesive tape and grease is the better than
the adhesive tape method, the latter of anti- penetrant effect is
very ideal.
THE MAINTENANCE PHASE
MAINTENANCE PHASE
In a lot of the field of maintenance, cleaning before penetrant testing is non-standard, just
using the solvent to wipe, especially for frequently used parts which defects are easily
blocked, maintenance surface cleaning can be reference to the following:
1. Clean the testing surface, wipe with clean cotton cloth which dip solvent remover.
2. Protection non-testing surface with polyethylene film and electroplating tape, to ensure
that the joint surface does not enter the etchant.
3. Brushed rework area about 2 min with 10% industrial sodium hydroxide (NaOH) solution.
4. We should keep etchant moist surface in the process of etching treatment. Note: the
etchant of aluminum has strong corrosive, should be a mandatory strictly abide by the
protection.
MAINTENANCE PHASE
1. Wipe corrosion surface to remove sodium hydroxide solution by water wet cloth.
2. Wipe industry solution surface with 10% nitric acid (HNO3) to neutralize sodium
hydroxide solution.
3. Wipe the rework area to remove nitrate by water wet cotton cloth. Then Wipe
with a clean, dry cotton cloth.
4. Remove polyethylene film, wipe with solvent remover wet cotton cloth, remove
any protection with those left on the surface residue.
5. Check the rework area again. If the defect indications appear again, it is
submitted to the engineering department again.
6. The remains of penetrant materials shall be removed after penetrant testing (e.g.,
developer).
THANK YOU