eddy current in aviation
TRANSCRIPT
Application of eddy current in Aviation
Window and door frames; Aircraft wheels; Pre-buy aircraft inspections; Surface crack high-frequency inspection; Subsurface low frequency inspection; Multi layer of metal crack detection; Part edges; Crack progression verification; Marking the start and end of a crack to facilitate stop drilling; Cracks around fasteners; Aircraft part extent of corrosion verification and damages
from mechanical peeling; Crack detection on Aluminum, Titanium, Iron, Stainless Steel,
Inconel, Nickel, Magnesium.
According to the Regulatory Documentation the eddy current is used on:
Equipment for manual eddy current testing
operating frequency setup range – from 50 Hz to 12 MHz;
generator output voltage (double amplitude) – from 0,5 V to 6 V;
adjusted gain range – 70 dB;signal phase change (range of signal
rotation from 0° to 360° with a step 0,1˚, 1°, 10°);
sampling frequency – up to 8000 measurements/sec. ;
digital signal filtering (there are 5 filter types: lowpass, highpass, bandpass, differencial, averanging);
Eddy current signal display: а) complex plane; b) mix of two frequences;
possibility to connect eddy current rotary scanner for testing of openings and encoder ;
user-frendly multi-channel interface;small dimenssions.
VD3-81 Eddycon
Equipment for manual eddy current testing
Eddycon CFrequency range 10 Hz – 16 MHzPhase adjustment 0 – 360 º with a step 0,1 º
Preamplification from minus 6 to 40 dB with a step 0,1; 1; 6 and 10 dB
Gain from 0 to 30 dB with a step 0,1; 1; 6 and 10 dB
Separate X and Y gain adjustment
from 0 to 30 dB with step 0,1; 1; 6 and 10 dB
Sampling frequency from1 to 10 kHz
Filters Lowpass, Highpass, Bandpass, Differential, Averaging
Testing mode Single-frequency, Double – frequency
Alarm frames Circle, threshold, sector, cutoff (trapezium).
Operation time from battery 8 hours
Despite small dimensions and weight the flaw detector Eddycon C has
specifications and capabilities that are not inferior to more dimensional
devices.
Probes for eddy current flaw detection
Various circuits for ECP connection: Reflection-absolute; Reflection-differential; Bridge-absolute; Bridge-differential; Single coil.Various types of ECP: Surface (for surface and subsurface
defects detection); Rotary (manual and dynamic); Special-purpose.
INSPECT WHEEL HALVES, WHEEL BASES, SIDE RIMS, OR PISTON HOUSING WITH CONTOUR BEAD SEAT AND PENCIL PROBE
APPLICATION OF EC NDT:
Probes for wheel inspection
Wide frequency range: 50-500 kHz for contour
bead seat probe; 0.2-6 MHz for pencil
probe.
Shielded and unshielded types.
Different type of form.
APPLICATION OF EC NDT:
Rotating Probe InspectionArea of ApplicabilityHoles in aluminum alloy material of conductivity 16.0 MS/m (27.6% IACS) to 28.0 MS/m (48.3% IACS) with a minimum thickness of 1 mm (0.039 in) and titanium alloy material with a minimum thickness of 1 mm (0.039 in).
Possible Damage : Fatigue cracks ≥ 1 mm (0.039 in), open to the surface, starting at the wall of the holes and extending in radial (crack length) and axial (crack depth) direction.
APPLICATION OF EC NDT:
APPLICATION OF EC NDT:
A(t)
XY
X(t) +Y(t)+XY
Hole inspection and different types of data visualization on EDDYCON C flaw detector
Rotating Probes:
Different types of probes design: rigid, expandable or flexible; fixed or adjustable; manual or for rotary scanner.
Range of inspected diameter – from 3,1 mm up to 25,4 mm.
Frequency range – from 100 kHz up to 6 MHz.
APPLICATION OF EC NDT:
Inspection for Surface Breaking Cracks in Aluminum Alloy Material and Non-Coated Titanium
APPLICATION OF EC NDT:
Inspection for Surface Breaking Cracks in:- Non Plated Ferromagnetic Steel Alloy
Materials;- in Cadmium Plated Ferromagnetic Steel Alloy
Materials.
APPLICATION OF EC NDT:
Evaluation of the length of surface breaking cracks detected when using a high-frequency eddy current (HFEC) inspection. HFEC Inspection for Surface Breaking Cracks in Aluminum Alloy Material and Non-Coated Titanium Material
APPLICATION OF EC NDT:
Display of signal from artificial notch 0,5 mm depth on aluminum reference block
Probes for surface inspection
Different types of probes design: straight; angle shaft.Different types of probes connector: Lemo 00, BNC Microdot
etc.; Triaxial Lemo.
APPLICATION OF EC NDT:
Non defect area
Defect area
mm
Calibration block for rivets imitation in the area of a rear pressure bulkhead and received signals.
APPLICATION OF EC NDT:
Example of rivets testing using ring probe with Eddycon C flaw detector in the area of a rear pressure bulkhead.
APPLICATION OF EC NDT:
Cracks location in the area of countersunk rivets in the 4th layer of a five-layer calibration block (а) and received signals (top-bottom) from the defect, defect-free rivet and gap.
a)
b)
Example of testing the multilayer covering near the door frame of aircrafts "Boeing 737-300, 737-400, 737-500" with Eddycon C flaw detector and cracks detection that may emerge and develop from rivets at a depth from 3.6 to 6.1 mm in different layers of a five-layer one-piece assembly with a total thickness of 13.68 mm.
Probes for subsurface inspection
Different types of probes connector.
APPLICATION OF EC NDT:
Various circuits for ECP connection: Reflection-absolute; Reflection-differential; Bridge-absolute; Bridge-differential; Single coil.
Application of ultrasonic in Aviation
parts of landing gears; aircraft wheels; walls of fuselage and pressure bulkhead; engine elements; multilayer metalwares for the presence of glue line defects; propeller blades; studs and screws for parts attachment; bearing frames of airliner wing control elements.
According to Regulatory Documentation for Boeing, Airbus, Bombordier aircrafts the following parts and
units are subjected for ultrasonic testing :
Portable ultrasonic flaw detector UD3-71
Equipment for manual ultrasonic testing
UD3-71 flaw detector – ultrasonic portable general-purpose flaw detector is intended for:• manual non-destructive testing of products for the presence of defects
such as inhomogeneity and discontinuity of material in raw stock, finished items, in-process goods, welded, soldered, bolt, riveted ant other joints;
• measuring the depth and other coordinates of defects;• measuring the thickness of various items at one-way access to them;• measuring the ratios of signal amplitudes, reflected from defects;• measuring the equivalent sizes of defects;• assessing the sound velocity in sundry materials.The flaw detector implements pulse echo, echo-images and echo-mirror
technique.The flaw detector implements two modes of information display A and B-Scans.Possibility to register and protocol of testing results.The flaw detector can be operated at temperature from minus 30 to plus 40 0 C.
manual testing of products for the presence of defects such as discontinuity and inhomogeneity of materials, finished and semi-finished items and welded joints; measuring the depth and other coordinates of defects; assessing the sound velocity of ultrasonic vibrations in
various materials; measuring the items thickness at one-way access to them ; thickness gauging of irregular shaped objects with the
capability to save the testing measurements into multi-dimension files ;
building the thickness slice and map; measuring the equivalent defect sizes; measuring the ratios of signal amplitudes, reflected from
defects.
Purpose:
Ultrasonic flaw detector SONOCON
Possibility to choose the software version SONOCON
thickness gauging of irregular shaped objects with the possibility to save the results of measurement into multi-dimensional files; building the thickness slice and map; Auto calibration of probe zero and auto selection of gain of receiving path during the measurement; continuous control of acoustic coupling.
Basic version “Thickness gauge+” version
universal manual ultrasonic flaw detector of general purpose.
Ultrasonic transducers
Specialized
Angle double crystal transducers
Contact straight -beam single crystal transducers
Contact straight -beam double crystal transducers
EMA flaw detector Emacon-01
Testing through the insulating layer or an air gap without applying the couplant; High testing sensitivity with shear waves and Lamb waves;Accuracy of measurement is up to 0,1 mm during thickness gauging.
EMA transducers
Specialized EMAT with the capability of spot measurement and scanning
Specialized EMAT with built-in wheels for measurement
Special-purpose applications:
To test the spindles of sliding assemblies placed on the middle section of outer airplane flap, P111-5-P6-MM-004 transducers with a special profile wedge, which have been set up on the NDT3038 calibration block are used.
Special-purpose applications:
Testing the areas of two ears of "Actuator Beam Arm"
Testing is carried out from the cylindrical surface by special transducer, including several wedges with various refracted shear angles into the inspected part, and special-applicant small-weight resonator with the frequency of 5 MHz.
Special-purpose applications:
Testing the crossbolt hole of main landing gear outer cylinder of Boeing 767
carried out with a 5 MHz frequency transducer. The crystal is set at an angle to give a 35 degree refracted shear angle in steel. The transducer case has a 0.985 inch radius to fit the outer diameter of the crossbolt bushing flange during the scanning. Crack-like defects developing as corrosive depressions on the inside surface of the outer cylinder are bound for testing.
Special-purpose applications:
Testing the wheel hub of the Boeing 767 main landing gear
Applied two P111-5-P8-R-003 transducers and one P111-5-P8-R-005 transducer which are put in special holders for testing.
Special-purpose applications:
Testing the mounting seats of hub bearing units of the Boeing 767 main landing gear
Mounting seats of hub bearing units are tested in two ways:by longitudinal waves in the thrust shoulder area and by shear waves in thearea of bearing body mounting site. Special transducers are used for the testing, consisting of 5 MHz resonator, special-applicant wedges with scanning assemblies allowing to carry out the scanning in a given area and with given parameters of ultrasonic waves introduced into the tested object.
Special-purpose applications:
Testing the aircraft wheel disks of the Boeing 767 main landing gear
Testing the fillets from the cylindrical surface to the thrust shoulder of wheel disks is carried out by surface 2.25 MHz frequency transducers.
Special-purpose applications:
The rear pressure bulkhead
Special P121-10-70-ММ transducer is used for testing. The transducer is set up on the NDT3001 calibration block which represents a plate of 2024 Aluminium Alloy with 0.81 mm thickness. Surface wave is generated in the calibration block which is reflected from the edge that simulates a crack in this case. Testing technique allows to detect cracks at a distance of about 28 mm from the transducer front edge.
Special-purpose applications:
Ultrasonic inspection of “АV” and “SV” items cases studs in operation can be carried out without studs dismounting from the item during engine-bench test and repair.
Ultrasonic flaw detection of pinch bolts of BOEING, AIRBUS airliners wheel webs is executed in immersion mode in local immersion tank.
Special-purpose applications:
Wheel disks of BOEING, AIRBUS airliners are tested by ultrasound for detection of discontinuities in different part sections. The probes of longitudinal, transverse and surface waves are applied.
Special-purpose applications:
The testing of one of the most important engine elements - stationary and rotary blades of gas turbine is the task of increase of reliability and operating life of gas turbine engine.
Special-purpose applications:
Section 51-40-00 Part 4. Using EMA flaw detector it is possible to carry out the bondtest inspection of two metal bonded parts according to NDT manual for Boeing.