Eddy current in aviation

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.


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.



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.


Inspection for Surface Breaking Cracks in Aluminum Alloy Material and Non-Coated Titanium


Inspection for Surface Breaking Cracks in:- Non Plated Ferromagnetic Steel Alloy

Materials;- in Cadmium Plated Ferromagnetic Steel Alloy

Materials.


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


Display of signal from artificial notch 0,5 mm depth on aluminum reference block


Fasteners inspection

Probes for surface inspection

Different types of probes design: straight; angle shaft.Different types of probes connector: Lemo 00, BNC Microdot

etc.; Triaxial Lemo.


Different types of subsurface cracks


Non defect area

Defect area

mm

Calibration block for rivets imitation in the area of a rear pressure bulkhead and received signals.


Example of rivets testing using ring probe with Eddycon C flaw detector in the area of a rear pressure bulkhead.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.


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.

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Eddy current in aviation