B787READINESS

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INTRODUCTION

Thisweekmarkstheintroduc=onoftheB787-9totheQANTASfleet

Thereisgreatexcitementandexpecta=onwithinourorganisa=onfortheaircraFanditspoten=altodeliverimprovedcomfort,performanceandsafetyforthecustomer.

WhatdoesthismeanforEngineering?Specifically,whatdoesitmeanforNDT?

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The Journey

InJanuary2003,BoeingannouncedtheB787asthereplacementproductforitscancelledSonicCruiserprogram.

ThiswasdrivenbytheairlinesshiFisopera=onstrategyfrom“hubandspoke”routesto“pointtopoint”routes.

AFernumerousproduc=onandflighttestdelays,thefirstaircraFwasdeliveredtoANAinSeptember2011

TheB787-8enteredservicewithJetstarinOctober2013.

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What is a B787?

TheBoeing787usesmorecompositematerialsinitsairframeandprimarystructurethananypreviousBoeingcommercialairplane.Approximately53%

Becauseoftheextensiveuseofcomposites,itisimportanttounderstandtermsandconceptsaboutcompositematerials.

Inaddi=ontomorecompositematerials,thegeometryofthe787structureisdifferentfrompreviousBoeingmodels.

Itisalsoimportanttounderstandthedifferencesbetweendamageevalua=onformetallicstructurescomparedtodamageevalua=onofcompositestructure.

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Material ApplicaAons

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Material SpecificaAon

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Challenges

IntheworldofSpecialistMaintenance,NDTinspectorsareauthorisedtoperformaprocess.Thereisnotypera=ngforNDTinspectors.

Infact,yourNDTinspectorisalreadyauthorisedtoperformthatprocessontheaircraFthathasn’tbeenbuiltyet!

However,inthePart145MOS,theAMOisrequiredtoensurethatacer=fyingemployeehasan“adequateunderstanding”oftheaircraForaeronau=calproduct.

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What do we need to do for our inspectors?

1)  Safety.2)  Structuralawareness.3)  Documenta=on.

4)  Applica=ons.

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Safety

WeneededtogenerateasafetyawarenesstrainingpackageforanyoneworkingontheaircraF.

TheB787usesmanynewelectro-mechanicalsystemsnotseenonpreviousfleets.

Employee’sneedtorecognisedangersandbealerttopoten=alhazards.

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Structural Awareness

QantasdevelopedastructuralawarenesstrainingpackageforallemployeesincontactwiththeaircraF.

TheNDTinspectoralsoneedstocompetentlynavigatetheSRM.

NotallB787’sareconstructedthesame.

TherearesignificantdifferencesbetweentheB787-8andB787-9.EachhavethereownSRM.

Theinspectorneedstobeawareofthemanufacturingtermsandtechniquesofthematerialsused.

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Structural Awareness

Fromtherela=velysimplestructures

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Structural Awareness

Tothemorecomplex

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Structural Awareness

AddStringers

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Structural Awareness

Andframes

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DocumentaAon

TheSRM(andAMM)usenewDataModuleCode(DMC)forS1000DdeliveryintoMaintenancePerformanceToolbox.

DeliveryofS1000DdataintoToolboxusesaStandardNumberingSystem(SNS)applyingaDataModuleCodes(DMC's)toeachSRMProcedure.EachDMChasmul=pleDisassemblyCodeswithinanATA(beginningat00Aandcon=nuingwith01A,02A,03Aandsoon)alongwithanInfoCodethatiden=fiesthetypeofSRMData.

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ApplicaAons

BoeingproducefortheAirlines,atoolingandequipmentmasterlistforEntryintoService

TheonlyNDTtoollistedinthemasterlististheGEnxFanBladeUltrasonicInspec=onKit–forpostbirdstrikefanbladeinspec=on

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ApplicaAons

AirplanehitbygroundequipmentFuselageBirdStrikeFuselageLightningStrikeFanBladeLightningstrikeFanBladeLeadingEdgerepairFuselageBondedrepairInspec=onWingLowersurfaceposttyreshredB787-9HorizontalandVer=calStabiliserLeadingEdgeskinsfors=ffenerdisbondB787-8HorizontalStabiliserLeadingEdgeforskintocoredelamina=onB787-9HorizontalStabiliserleadingedgeHybridLaminarFlowControl(HLFC)forskintocoredelamina=onVer=calStabiliserleadingedgeskintocoredelamina=onWingLeadingedgeheatedandunheatedslats

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ApplicaAons

Damagedetec=oninBMS8-276material

BoeingNDTmanualallowstwomethods:

GuidedAscanat4mmincrements

TCG

Timeconsuming

Nopostinspec=onanalysis

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ApplicaAons

RecommendedistheUltrasonicLineararray(PAUT)withatwodimensionalencodersystem

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ApplicaAons

BondedRepairInspec=on

Cscanmethodisrecommendedwhereaccessandsurfacecondi=onsaresa=sfactory.

Providessignificantpostinspec=onanalysis

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ApplicaAons

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Bondlineflaws

ApplicaAons

PorosityCalcula=ons

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ApplicaAons

B787-9

HorizontalStabiliser

LeadingEdgeskin(Hybrid)LaminarFlowControl(HFLC)

EmploysanominatedBondtester(resonancemode)

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ApplicaAons

Ver=calStabiliserLeadingedgeskintocore

EmploysaBondtesterinthepitch/catchmodebutisonlyapplicableiftheAluminiumerosionshieldisbondedtotheGRFP

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ApplicaAons

GEnxFanBladeInspec=onpostBirdStrike

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ApplicaAons

RampDamageChecker

TheproceduretousetheRDCiscontainedintheSRM(nottheNDTmanual)

Therearelimita=onswheretheRDCisused

Onlylaminatedstructures

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ApplicaAons

RampDamageChecker

ThisisabasicUltrasonicInstrumentcalibratedontheaircraFstructure.

Itdisplays“Good”or“Bad”andwillneedtoberecalibratedforeachthicknesstobeinspected

ItisdesignedtobeusedbyNonNDTpeople,however,indica=onsshouldbeverifiedbyinstrumentedNDTmethods

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Resources

Thesophis=ca=onoftheaircraFcomparedto“metal”types,andpoten=alrouteopportuni=esalsopresentschallengesonwheretoposi=onresources.

Thehighcostofini=alequipmentsetup,andinspectorfamiliarisa=on/trainingisprohibi=veinasmallfleet.

Consolida=on,resourcepoolingandrecogni=onofotherMRO’s(outsidetheAustralianregula=ons)tosupportthefleetmustallbeconsidered.

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Summary

Toensure“adequateunderstanding”weneedtoconsider,trainanddocument

1)  Safety.2)  Structuralawareness.3)  Documenta=on.

4)  Applica=ons.

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Acknowledgements

Boeing787StructuralAwarenesstrainingpackage

AustralianAvia=onmagazine

Boeing787NDTmanual

BoeingB787-9SRM

TheAustralianBusinessTraveller

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