Study And Comparison Of Different Fabrication And NDT - NDT.net
Sponsored by USAF - AFRL/RX - ndt.net · The Air Force Nondestructive Inspection Improvement...
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The Air Force Nondestructive
Inspection Improvement Program
David Forsyth2, Mark Gehlen3, Jeff Guthrie1, Mark Keiser2, Ronald Kent1, Michael Morgan1, Carlos Pairazaman3, Darren Stamper1, Damaso Carreon4
1. Alion 2. TRI/Austin 3. UniWest 4. USAF
Sponsored by USAF - AFRL/RX Government POC: Damaso A Carreon AFRLRXSST
2010 ATA NDT Forum 20 – 23 September, Albuquerque
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Overview
• Why?
• Program Description
• Typical Findings
• Solutions
– Technical Orders
– Technology Insertion
– Verification and Validation
• Conclusions
• Acknowledgements
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Why?
• One of many efforts in continual improvement of Nondestructive Inspection (NDI) performance at United States Air Force (USAF) depots and field units.
• Inspection technique documents (Technical Orders or TO’s), equipment anywhere from 10 to > 40 years old. – Known issues, but lack of available resources to deal
with them
– Personnel are busy getting the aircraft back into service!
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Why –
Technical Orders - example
4
• Written instructions
are to inspect x
number of
fasteners here!
• But there’s a lot
more than x!
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Why –
POD and POI
• POD = Probability Of Detection
• Given:
– Defined inspection technique
– Defined discontinuity type on defined
inspection target
• Probability Of Detection is a function
describing the detection of the
discontinuity as a function of its size
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Why –
POD and POI
• POI = Probability Of Inspection
– Even less clear than POD.
– Is inspection performed at all?
– Is inspection performed correctly?
• EFFECT ON RISK OF POI < 1.0 IS
SIGNIFICANT
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Why –
How to affect POI
• Is inspection being done?
• Is inspection being done correctly?
– Does T.O. clearly indicate location, scan plan,
inspection technique?
NDI Improvement Program
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Overview
• Why?
• Program Description
• Typical Findings
• Solutions
– Technical Orders
– Technology Insertion
– Verification and Validation
• Conclusions
• Acknowledgements
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Program Description –
The NDI Improvement Program
• USAF fleet Aircraft Structural Integrity Program
(ASIP) managers tasked to identify, rank control
points on aircraft based on structural integrity
parameters:
– Damage tolerance life exceeded by fleet leader?
– Single load path?
– Cracks found in fleet?
• Some fleets have control points with “yes” to all
the above
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Program Description –
Progress
• Already delivered:
– 90 inspection techniques have been audited based upon the prioritization
• Re-written procedures provided to USAF to modify existing Technical Orders (TO’s)
– Two new “probe kits” have been delivered to provide improved POD/POI
• Targets chosen with USAF guidance to provide highest ROI
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Program Description –
Approach
• Experienced inspectors (ASNT Level III or
better in at least one related discipline)
witness actual inspections at USAF
depot/field sites.
• Standard, simple semi-quantitative audit
form to capture results and provide
direction for improvement.
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Overview
• Why?
• Program Description
• Typical Findings
• Solutions
– Technical Orders
– Technology Insertion
– Verification and Validation
• Conclusions
• Acknowledgements
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Typical Findings
• There are a number of common (occasional) issues with TOs. – Wrong references in procedure to other applicable paragraphs in
T.O.
– No clear description where to inspect using the text description
– No clear description where to inspect using the drawings
• There are a number of control points where an assumed NDI capability is better than the capability defined in the new USAF guidelines. – This can have severe impact on operations.
• See Harris et al. at ASIP 2009
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Typical Findings
• There are categories of inspections that
are common across many fleets, that
could be improved with new probes.
– Raised head fasteners
– Edges
– Radii
– Flat area scanning
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Overview
• Why?
• Program Description
• Typical Findings
• Solutions
– Technical Orders
– Technology Insertion
– Verification and Validation
• Conclusions
• Acknowledgements
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Solutions – Technical Orders
• Working with AF personnel to fix simple
issues through established processes of
TO updates.
– TO’s provided to the AF NDI Managers in
format ready for insertion
– by end of calendar 2010, over 200 technical
orders audited, updated
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Solutions – Technology Insertion
• USAF guidelines allow smaller “detectable crack size” for use of probes with reduced degrees of freedom in movement
• New eddy current probe designs being used in other AF programs. – modified for cross-cutting application
• Probes compatible with existing USAF standard equipment.
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Solutions – Technology Insertion -
Raised Head Fastener Inspection
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Solutions – Technology Insertion –
Raised Head Fastener Probe
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Modified US-2103 Swivel Head Edge Probe
(Shoe rotated 90 degrees)
Solutions – Technology Insertion -
Edge Inspection
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Solutions – Technology Insertion –
Edge and Surface Inspection Probe Kit
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Solutions – Technology Insertion –
Radii Inspection and Probe
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Solutions - Verification and Validation of
New Probe Designs
• Verify
– That probes work (form, fit, function) on the
identified opportunities.
• For example, tight access may eliminate possibility
to use new probes.
• Validate
– Estimate POD.
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Audience Participation
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Solutions – Verification and Validation
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Solutions – Verification and Validation
• What is validation for NDI? – Probability Of Detection (POD)!
• How to get it? – MIL-HDBK-1823
• Can use – per MIL-HDBK-1823:
• Similarity
• Models
• Empirical Studies
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Crack Length (mm)
Pro
ba
bil
ity
of
De
tec
tio
n
Inspection Results
POD
95% confidence on POD
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Solutions – Verification and Validation
• New edition of MIL-HDBK-1823 explicitly
allows for use of models, similarity in POD
estimation.
– Minor changes to probes already validated
require minimal effort to validate.
– Each diameter of raised fastener probe does
not require a “full POD study”.
– More cost-effective validation than fully
empirical approach.
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Solutions – Verification and Validation –
NDI Performance metrics
• Probability of Detection (POD)
• “Probability of Inspection” (POI)
• False Call Rate
• Cost/time to perform inspection
– Equipment capital and ongoing
– Disassembly requirements for access
– Inspector time
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Solutions – Verification and Validation -
Ongoing
• Using existing USAF specimen set from
previous studies.
– Can directly compare results to a large set of
pencil probe results.
• POD, POI, FCR, time, cost
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Solutions – Verification and Validation -
Ongoing
• USAF QAPA Specimen and Pencil Probe
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Solutions – Verification and Validation
- Ongoing
• USAF QAPA Specimen and RHF Probe
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Solutions – Verification and Validation -
Ongoing
• Multiple USAF inspectors at each depot
will inspect the QAPA specimens with the
RFH probes.
– Trial modeled after the QAPA study.
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Overview
• Why?
• Program Description
• Typical Findings
• Solutions
– Technical Orders
– Technology Insertion
– Verification and Validation
• Conclusions
• Acknowledgements
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Conclusions
• USAF guidance for reliably detectable crack size, pencil probe around a fastener head: – 0.200” of exposed crack length
• RHF probe preliminary results – ~ 0.100” of exposed crack length
• Reduced degrees of freedom of movement of the RHF probe may translate into reduced inspector to inspector variability. – This is key!
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Conclusions - POD
• Bryce Harris, Time Jesske, Kimberli Jones, Sean McIntyre, “Impacts of Nondestructive Inspection Capability
Guidelines for USAF Structures”, presented at ASIP 2009
Hypothetical capability of 0.100”
plus covered length provides 1900
FH re-inspection interval
ASSUMED
CAPABILITY
GUIDELINES FOR PENCIL
PROBE CAPABILITY
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Conclusions - POI
• What makes an inspection not valid?
– Not done.
– Not done correctly.
• Equipment, calibration, probe manipulation,
recording
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Conclusions - POI
• How did your two circles look?
• Published literature indicates POI is real in large POD trials. – “The estimated background miss rates from the 45
inspections ranged from 0 to 0.168, with an overall average of 0.024”
– Floyd Spencer, Don Schurman, Reliability Assessment at Airline Inspection Facilities Volume III: Results of an Eddy Current Inspection Reliability Experiment, DOT/FAA/CT-92/12, III, May 1995
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Conclusions - POI
• Hard (impossible?) to know how this translates to field results.
• We will evaluate POI as part of the validation study.
• RHF probe should improve some of the contributing factors to POI problems – Probe tilt out of spec
– Repetitive, tiring, manually difficult
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Conclusions - FCR
• Very few false calls in the QAPA study.
• False call rate in field is unknown.
• We will evaluate the FCR in the validation
study.
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Conclusions - Time
• We will measure the time required for the
RHF probe inspection on the QAPA
specimens and compare to the pencil
probe inspection.
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Conclusions - Cost
• RHF probes are more expensive than pencil probes.
• RHF probes use the current USAF ET equipment.
• RHF probes will require some additional training. – Draft TO and draft training package are being delivered to USAF
as part of this effort.
• Reduced inspection intervals are a big cost benefit!
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Conclusions – Misc.
• Experimental work shows no effect of
fastener material on RHF probes.
– Non-conductive, Al, Ti, Steel
• Will evaluate other substrate materials
– Using similarity approach of MIL-HDBK-1823
• Edge probes and area probes also to be
validated.
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Summary
• Program continues with a “spiral”
approach.
– Review SOFI/ALC identified procedures.
– Implement improvement in TOs.
– Identify opportunities for technology insertion.
– Verify and Validate new technology.
– Implement new technology into depot and
field.
Year 1 Year 2
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Acknowledgements
• Program Oversight from the AF NDI Office (AFRL/RXSST)
• Funded by the Air Force Materiel Command’s Depot Maintenance Operations Division (HQ AFMC /A4DM)
• Great cooperation from USAF personnel at all levels.
– Oklahoma City Air Logistics Center (OC-ALC)
– Warner Robins Air Logistics Center (WR-ALC)
– Ogden Air Logistics Center (OO-ALC)
– Aeronautical Systems Center - Engineering Directorate (ASC/ENFS)
– Air Force Research Laboratory’s Material Integrity Branch (AFRL/RXSA)
– Air Force Research Laboratory’s Nondestructive Evaluation Branch (AFRL/RXLP)
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Public Service Announcement
• DoD funded resource you can access:
– http://ammtiac.alionscience.com
• DoD DDR&E is funding an update to the
(formerly NTIAC) POD Handbook.
– please contact me for further information
– please contact me if you have data that can be
included
– 512-263-2101