INSPECTION

METHODOLOGY
The objective of NDI (Non-
Destructive Inspection) is to
detect discontinuities, flaws
and other defects in
a structure or component, not
normally detectable by
naked-eye, in such a manner
that the test does not harm
the material in any way
Common purpose of inspection
- To determine airworthiness
- Classification of damage
- Determine proper method of repair
- Determine extent of damage
AIRCRAFT INSPECTION METHODS

1. Visual inspection (external/surface defects) Detect resin rich @ poor area,

delamination, fiber break out, cracks & others.

2. Tap test (internal & surface defetcs) Laminated parts is tapped with a coin or small
metalic objects, detects delaminations close to surface. Comparison between a sharp and
dull sound. False readings due to parts thickness, fasteners and previous repairs.

3. Ultrasonic (internal) - Detecting internal damage such as delaminations, core crush.

Consist of pulse echo method and trough transmission method. Pulse echo (laminated
structure) where the echo is sends and receives & displayed on an oscilloscope. Trough
transmission uses 2 transducers. (bonded core structures)

4. Radiografi (internal) Used to detect differences in thickness or differences in physical

density compared to actual surfaces. Detects internal cracks, water entrapped, extent &
size of damage and foreign objects.

5. Thermography - Detects differences in temperatures variations at the surface of damage

parts. Factor references is the thermal conductivity & standards ref.

6. Dye penetrant

7. Acoustic immesion (internal)

8. Others..
VISUAL INSPECTION

A method of inspection that uses visual to

determine the approximate defect or damage.
Defects visible to naked eye.
Visual Inspection
Magnifying Glass
To inspect the external/
surface condition of the
composite defect.
Cannot determine the
extend of the internal
defect.
Need to accommodate with
more advanced equipment.
Use at accessible place.
Inspection Mirror
Assist inspection to the
hard to reach location.
Need torchlight/flash light
to assist in inspecting the
defect.
Videoscope/ Borescope
To assist visual
inspection in closed
structure ie,
integrated fuel tank
structure, hard to
inspect places.
Have video
streaming and
internal memory
TAP TEST/ RESONANCE FREQUENCY

A method of inspection by lightly knocking the

expected flaws or damage by listening for
variations in the tapping sound. Easy and cheap.
Electronic Tap Hammer
Uses the wave form from
the impact.
The value indicates the
variation of the material
density.
The higher the variation
from the reference
reading indicate defect.
 ULTRASONIC INSPECTION

A method of non-destructing testing which

utilizes a high frequency sound energy to
determine the structural integrity of a material.
Type of Ultrasonic Inspection
Pulse- Echo
High ultrasonic energy
is transmitted and
received by one
transducer.
Energy is transmitted
into the part and sonic
energy is reflected
from internal reflective
surface
Mainly for LAMINATED
STRUCTURE
 Type of Ultrasonic Inspection
Through Transmission
Ultrasonic energy is
transmitted by one
transducer and received
by another.
Located at the opposite
side.
Suitable for HONEYCOMB
STRUCTURE
The C-scan results show high ultrasonic through-transmission levels in regions of the
composites panel where NO DEFECTS were present (yellow areas), while the linear
defect strings showed up clearly as areas of REDUCED TRANSMISSION (blue-
green). The degree to which the defects reduced the through-transmission levels
appears to be related to the depth of the defects
Other Type of Ultrasonic Inspection

Reflected Through
Transmission
Similarto TT but have
reflector on the other
side.
Procedures/Method of Ultrasonic

Immerse Inspection
Use water as medium to
transmit ultrasonic
energy from the
transducer to the part.
The transducer will pass
through at a preset
coordinate.
Either pulse echo or TT is
applicable
Immerse Inspection
Procedures/Method of Ultrasonic

Contact Inspection
Transducerhave
direct contact with
part.
Types of Scanning (UT)

A-Scan
an amplitude
modulation scan.
gives the information
in the form of one
dimensional.
used to detect the
presence of flaws
(defects) in the
materials.
 Types of Scanning (UT)
B-Scan
Producea two-
dimensional, cross-
sectional view
Types of Scanning (UT)
C-Scan
Two dimensional
scanning that
produces length
and width taken
from top view.
C-Scan image showing DELAMINATION (green) in
thick section composite
 RADIOGRAPHY OR X-RAY

A method to detect internal defects by exposing

parts to x-ray or gamma ray radiation.
Radiography
An X ray source to
pass high energy
radiation.
The energy is
absorbed and
transmitted through
the part.
The x-ray paper will develop based on the
density of the material.
 INFRA RED / THERMOGRAPHY

A method to detect internal defects by looking at the temperature & heat

variations at the surface of the inspected parts.
 INFRA RED / THERMOGRAPHY
A sample to be tested is
heated at its surface by an
intensity source.
The heat penetrates into the
interior of the sample as a
thermal wave and any
change in the properties of
the sample material such as
cracks, cause a change in the
propagation characteristics of
the wave & any defect is
revealed by a local change in
the phase angle
 INFRA RED / THERMOGRAPHY

By recording the
surface temperature
of the sample with an
IR camera, the
temperature-time
function of the image
can be analyzed on a
computer.
 Visual Tap Test A-Scan C-Scan X-Rays Thermal Dye Penet
Surface delams B A B A B A N/A
Deep Delams N/A C A A B B N/A
Full Disbond B B A A B A N/A
Kissing Disbond N/A C C C N/A N/A N/A
Core Damage B B C A A B N/A
Inclusions B B A A A A N/A
Porosity B N/A B A N/A N/A B
Voids B B B B B B B
Backing Film N/A B B B B B N/A
Edge Damage A B B A A B A
Heat Damage B B B B N/A B N/A
Severe Impact A A A A C A A
Medium Impact A A A A N/A C C
Minor Impact C C C C N/A C N/A
Uneven Bondline C N/A C C C C N/A
Weak Bond N/A N/A N/A N/A N/A N/A N/A
Water in Core N/A B C A B A N/A

A = Indicates damage where the technique scores well

C = Indicates damage where the technique is not good
N/A = Not Applicable

A basic comparison between The non-destructive inspection techniques.

 THERMOGRAPHY

REPAIR

temperature & heat variations

 THERMOGRAPHY

temperature & heat variations

 THERMOGRAPHY

temperature & heat variations

A delamination (circled in the video image) in a carbon-fiber composite panel
using tap test and infrared imaging.
Microwave image of a region of core crushing in a 3.5 mm, E-fiberglass skinned +
PVC foam cored sandwich sample. Defect produced by a spherical impact.