ANK 315 AIRCRAFT MAINTENANCE INTRODUCTION TO...
Transcript of ANK 315 AIRCRAFT MAINTENANCE INTRODUCTION TO...
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AIRCRAFT DESIGN DEPARTMENT
The Faculty of Power and Aeronautical Engineering, Warsaw University of Technology
1
Kamila Kustron Ph. D.
ANK 315 AIRCRAFT MAINTENANCE
INTRODUCTION TO DIAGNOSTICS
NDT, SHM
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NON-DESTRUCTIVE TESTING
The need of non-destructive testing (NDT) application in aviation demands much of the equipment and technique makers qualification what is connected with a great variety of shape and complexity of testing units
Thereby, it is usually necessary to test the areas of stress concentration: holes for fasteners, panels edge, fillet transitions etc. In operation it is often essential to carry out NDT without removing the layer of paint-and-lacquer coating or sealant what excludes the usage of penetrant and ultrasonic techniques. In many cases there is no two-way access what makes it impossible to apply X-ray NDT technique
Moreover, it is often necessary to perform NDT in field conditions and airfield conditions During field service of aircrafts an operator with the equipment should be located directly on the wing or stepladder
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Non Destructive Testing NDT NDE NDI
continuous damage monitoring
Structural Health Monitoring (SHM)
Health and Usage Monitoring System (HUMS)
Engine Monitoring System (EMS)
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NON-DESTRUCTIVE TESTING
NDT TECHNIQUES
OBSERVE AND DIRECTLY
DEFECT DAMAGE
VISUAL/OPTICAL,
ULTRASONICS,
SHEROGRAPHY,
THERMOGRAPHY,
etc.
STRUCTURAL HEALTH
MONITORING
DETECT AND MONITOR USING
INDIRECT MEASUREMENTS
VIBRATION/MODAL ANALYSIS,
ACUSTO-ULTRASONICS,
FIBER BRAGGS GRITINGS
etc.
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Spectography
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VISUAL INSPECTION
1ST IS DIRECT VISUAL INSPECTION USE
BOROSCOPES, FIBEROSCOPES WITH REAL-TIME
VIDEO FOR DIRECT OBSERVATION
ALL HUMAN SENCES INVOLVED
HIGHLY DEPENDENT ON CAPABILITIES
OF OBSERVER, WHO IS TRAINED TO FIND
AND ASSESS CHANGES IDENTIFING DAMAGES
THERE ARE TWO GROUPS:
2ND IS INDIRECT VISUAL INSPECTION BASED ON
EXAMINATION OF PHOTOGRAPHS, RADIOGRAPHS
OR VIDEOTAPES
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VISUAL INSPECTION
VISUAL AIDS SUCH AS LIGHT SOURCES,
MAGNIFICATION DEVICES AND SENCORS
FOR REMOTE VIEWING EMPLOYED
UP TO 80% OF CRACKS ARE FOUND BY
VISUAL MEANS
INEXPENCIVE, HIGHLY PORTABLE,
IMMEDIATE RESULTS, MINIMAL
TRAINING
APPROPRIATE FOR ONLY SURFACE
DEFECTS, DAMAGES
HUMAN FACTOR
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VISUAL INSPECTION
+ INEXTENSIVE, HIGHLY PORTABLE,
IMMEDIATE RESULTS, MINIMAL TRANING
- ONLY SURFACE DEFECTS, CLEANING
REQUIRED, VISUAL ACCESS REQUIRED,
HUMAN FACTOR
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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LIQUID PENETRANT INSPECTION
RELATIVELY SIMPLE BUT EFFECTIVE TECHNIQUE
FOR LOCATING SURFACE CRACKS
APPLICABLE TO MANY MATERIALS
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INVOLVES
FLOODING SURFACE
OF TEST OBJECT
WITH LOW-
VISCOSITY FLUID.
FLUID SOAKS INTO
CREVICES VIA
CAPILLARY ACTION
PENETRANT IS CLEANED AND DEVELOPER IS APPLIED TO DRAW OUT
PENETRANT REMANING BETWEEN CRACK FACES
DEVELOPER PROVIDES CONTRASTING BACKGROUND
AND BLOOMING EFFECT TO ENHANCE CRACK VISIBILITY
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Liquid penetrant inspection
PENETRANTS CAN BE FLUORESCENT
AND VIEWED UNDER SUITABLE e.g. ULTRAVIOLET LIGHT
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LIQUID PENETRANT INSPECTION
+ PORTABLE AND WELL SUITED FOR FIELDWORK.
INEXPENCIVE AND REQUIRES MINIMAL SKILLS.
SENSITIVE TO SMALL DISCONTINUITIES. CAN BE APPLIED
TO NONPOROUS MATERIALS. FLAW ORIENTATION DOES
NOT USUALLY POSE A PROBLEM
- ONLY SURFACE ANOMALIES. MUST HAVE ACCESS TO
SURFACE. STRESSES AT SURFACE CAN CAUSE
UNCERTAINLITY. SIGNIFICANT SURFACE
PREPARATION REQUIRED. FAIRLY SLOW DUE TO
PREPARATION, DWELL AND CLEAN UP
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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Magnetic Particle Inspection
FERROMAGNETIC TEST PIECE IS MAGNETISED. MAGNETIC FLUX LEAKAGE FIELDS ARE DETECTED THROUGH THE ADDITIONAL OF SMALL PARTICLES WHICH MIGRATE TO THE FLUX LEAKAGE
CAN DETECT SURFACE AND NEAR SURFACE FLAWS
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Magnetic Particle Inspection
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Magnetic Particle Inspection
+ COMPLEX SHAPES READILY TESTED. FAIRLY
PORTABLE AND RELATIVELY INEXPENSIVE.
SENSITIVE TO SMALL SURFACE(OR NEAR-SURFACE)
DFECTS. REQUIRES MODERATE SKILL LEVEL.
RELATIVELY QUIK RESULTS
- LIMITED TO FERROMAGNETIC MATERIALS.
SURFACES MUST BE ACCESIBLE. LARGE ELECTRIC
CURRENT CAN BE REQUIRED. MAY NEED TO
MAGNETIZE OBJECT. LIMITED TO SURFACE
AND NEAR SURFACE DEFECTS. SURFACE FINISHES
MAY NEED TO BE REMOVED. FLAW DETECTION
SENSITIVE TO MAGNETIC FIELD ORIENTATION
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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Conductive material
Coil Coil's magnetic field
Eddy currents
Eddy current's magnetic field
EDDY CURRENT TESTING GENERATES SMALL ELECTRICAL CURRENTS IN TEST PIECE BY MEANS OF VARYING ELECTROMAGNETIC FIELD FROM COIL
THESE EDDY CURRENTS DEVELOP REVERSE MAGNETIC FIELD THAT IS SENSED BY COIL
Eddy Current Inspection
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Eddy Current Inspection
ANYTHING THAT AFFECTS EDDY CURRENTS (E.G. CRACKS, POROSITY, INCLUSIONS) WILL MODIFY SECONDARY MAGNETIC FIELD AND BE SENSED BY IMPEDANCE CHANGE IN COIL
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Eddy Current Inspection
Edddy current inspection is a surface method and can only detect defectts up to a depth of around 6 mm
The method requires calibration(artificial defects such as saw cuts, holes etc.)
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Eddy Current Inspection
Three probe types: Surface probes for testing plates Encircling probes for bars and rods Bobbin probes for inspection of tubes
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Eddy Current Inspection
Practicing of local corrosion damages detection technique
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Eddy Current Inspection
Two scanning types are applied: circular and zigzag
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Eddy Current Inspection
+ SENSITIVE TO SEVERAL STRUCTURAL AND
METALLURGICAL VARIABLES LEADING TO MANY
APPLICATIONS. MODERATELY FAST TECHNIQUE
GIVING INSTANTANEOUS INDICATION. PORTABLE.
CAN DETECT SMALL SURFACE OR NEAR-SURFACE
ANOMALIES. MINIMAL PART PREPARATION
- TEST OBJECT MUST BE ELECTRICAL CONDUCTOR.
SURFACE MUST BE ACCESSIBLE TO PROBE.
LIMITED DEPTH OF PENETRATION. SKILL AND
TRAINING REQUIRED TO INTERPRET RESULTS. CAN
BE TIME CONSUMING FOR LARGE INSPECTION
AREAS
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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RADIOGRAPHIC INSPECTION
RADIOGRAPHY IS ONE OF THE OLDEST NDT METHODS FOR LOCATING INTERNAL AND EXTERNAL ANOMALIES
EXPLOITS CHARACTERISTIC OF MANY MATERIALSTO DIFFERENTIALLY ABSORB AND PASS HIGH-ENERGY RADIATION
SOURCE OF RADIATION MAY BE X-RAYS, GAMMA RAYS OR NEUTRONS
VARIATIONS IN ABSORPTION WHICH RESULT FROM CHANGES IN MATERIAL DENSITY OR THICKNESS ARE RECORDERED USING EITHER FILM OR REAL-TIME DETECTORS
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APPLICATIONS INCLUDE:
CHECKING FOR POROSITY IN CASTINGS OR WELD DEFECTS
DETERMINING INTERNAL GEOMETRY
DETECTING CRACKS IF PROPERLY ORIENTED
LOCATING AND MEASURING CORROSION THINNING
RADIOGRAPHIC INSPECTION
ROBOSCAN 2M AERIA
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Radiographic Inspection
+ CAN DETECT INTERNAL AND EXTERNAL DEFECTS.
APPLICABLE TO WIDE VARIETY OF SOLID
MATERIALS AND COMPLEX SHAPES. PERMAMENT
RECORD OBTAINED. MINIMAL PART PREPARATION.
REAL-TIME VIEWING POSSIBLE. 3D IMAGING
POSSIBLE
- SIGNIFICANT SAFETY ISSUES. TWO-SIDES ACCESS
TO TEST PIECE GENERALLY REQUIRED. DIRECTION
VERY SENSITIVE TO FLAW ORIENTATION. HIGH
DEGREE OF SKILL AND EXPERIENCE. RELATIVELY
EXPENSIVE. USUALLY SOME DELAY IN OBTAINING
RESULTS
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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Acoustic Emission
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•Resonance test method
•Pitch/catch swept test method
•Pitch/catch impulse test method
•MIA(Mechanical Impedance Analysis)
test method
•Eddy sonic harmonic test method
•Tap test
Sonic/Resonance
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
• Sherography
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f
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
Oscilloscope, or flaw
detector screen
Ultrasonic Inspection (Pulse-Echo)
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2-D + colour
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Ultrasonic Inspection
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9 NDT TECHNICS ARE USED IN AVIATION
• Visual, Optical
• Liquid Penetrant
• Magnetic
• Eddy Current
• Radiography (X-ray/ gama ray)
• Sonic/Resonance
• Ultrasonic
• Infrared Thermography
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THERMOGRAPHY Infrared thermography (IRT), thermal imaging, and thermal video are examples
of infrared imaging science. Thermographic cameras detect thermograms. Since
infrared radiation is emitted by all objects above absolute zero according to the
black body radiation law thermography makes it possible to see one's environment
with or without visible illumination.
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SHEAROGRAPHY
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MEASUREMENTS OF DIMENSIONS
DIRECT METHODS OPTIC MEASURES
http://img.directindustry.com/images_di/photo-g/optical-sensor-for-coordinate-
measuring-machine-cmm-5693-2649407.jpg http://www.mitutoyo.co.uk/media/wysiwyg/landingpages/cmm.jpg
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SUMARY: SURFACE METHODS
MAGNETIC LIQUID PENETRANT
OPTIC/VISUAL SHEAROGRAPHY
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SUMMARY: UNDERSURFACE METHODS
EDDY CURRENT
rysynki pochodzą z udostępnionych slajdów z przedmiotu
„Materiały lotnicze”
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VOLUME INTERIOR METHODS
ULTRASONIC RADIOGRAPHY
http://www.hadtek.com/images/clip_image002.jpg
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SHM – Structural Health Monitoring
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SHM
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SENSORS
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REDUKCJA MASY DLA ELEMENTÓW KOMPOZYTOWYCH
Ważne jest pozyskanie informacji w przypadku struktur
kompozytowych o fizycznych własnościach,
uszkodzeniach, uderzeniach i rozkładach naprężeń i
odkształceń podczas użytkowania SP. Informacje służą do
poprawy elementów konstrukcyjnych bądź systemu
eksploatacji SP
Dla kompozytów powinno być objętych działaniem SHM 8
obszarów
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