a320 rod eye end magnetic particle inspection in-service feedback
TRANSCRIPT
Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1
AIRBUS A320 Rod Eye End Magnetic Particle Inspection In-Service Feedback
The 53rd Annual ATA NDT Forum-Albuquerque, New Mexico-2010
Presented by
Steven CRUMMACKSENIOR NDT ENGINEER,CUSTOMER SERVICES, AIRBUS.
September 2010
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Content
IntroductionComponent Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion
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In-Service Feed BackAIRBUS CUSTOMER SUPPORT
inspection
Introduction
Reject RateProcedure
Tooling
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Content
IntroductionComponent
Elevator Servo Actuator Rod Eye EndIn-service finding Rod Eye End Rupture
Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 4
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Component
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 5
Part Number 341203-XXX(Cadmium Plated, Stainless Steel 15NCD16)
A320 Elevator Servo Actuator Rod Eye End
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Component
Semptember 2010
A320 Elevator Servo Actuator Rod Eye End
Part Number 341203-300
Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 6
Current Part Numbers 341203-300/400/500
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Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1
Component
Page 7
One case of elevator servo control disconnection experienced on A320 Family.
Rupture occurred at level of servo control rod eye-end .
Operators were informed thru OIT .
In-service finding Rod Eye End Rupture
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Content
IntroductionComponent Thresholds and Interval
AimService Bulletin
ProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 8
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Thresholds & Intervals
Semptember 2010
Inspection aim, ensure servo-control disconnection does not occur, before threshold or between Intervals.
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Thresholds & Intervals
SB A320-27A1186Threshold: 5,000 flight cycles.Interval: 5,000 flight cycles.
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 10
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Content
IntroductionComponentThresholds and IntervalsProcedure
Method and samplingToolingField StrengthInterpretationDe-Magnetisation
POD (Probability Of Detection)In-Service Customer feedbackConclusion
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Procedure
AOT/SB A320-27A1186 Magnetic Particle Inspection
Workable over range facilities available to our operators.
Sampling completed in maintenance environment.
Verified 5mm(0.196 inch) x 0.5 mm(0.0196 inch) crack detectable.
Sampling confirmed a rejection rate of 15%.
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Method and Sampling
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Procedure
Semptember 2010
Stationary bench.Magnetised head stocks. Note: Not current flow.
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Tooling
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Procedure
Direct Current avoids field concentration in the Cadmium plating.
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 14
Defects originate in the base material.
Tooling
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Procedure
Semptember 2010
Field strength: below saturationIncrease crack resolution Reduce background fluorescence
Magnetic field Indicator shows working value of1990 A/m
Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 15
Field Strength
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Procedure
Semptember 2010
Misleading artefacts Eliminated under magnification.
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Once seen, there is no doubt over a genuine crack.Interpretation
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Procedure
Avoids intensifying artefacts(spurious indications) during Indication confirmation.
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 17
Before each magnetisation, de-magnetise.
De-Magnetisation
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Content
Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion
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POD (Probability Of Detection).
Semptember 2010
POD ( 90/95) criteria
90% is the probability of detection,
95% is the level of confidence (confidence interval)
False alarm rate to be considered.
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Content
Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedback
Coil or BenchBackground fluorescenceResidual field Magnetic Yoke
Conclusion
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 20
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In-Service Customer feedback
Semptember 2010
Widely available,Variable field strength.
Field strength constantIn area of interest.
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Magnetised heads Encircling coil
Coil or Bench?
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In-Service Customer feedback
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 22
Some customers internal standard practices required high sensitivity: Zero crack tolerance.
Background fluorescence was reduced by:Solvent based spray to remove excessive fluorescence. Extension of dwell time to resolve indication.
With effect of:
Background Fluorescence
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Difficult to resolve indications under magnification
Not practical to categorise as cracks or otherwise. Convention states, call indications cracks.
Result, increased sensitivity over and above SB.
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 23
In-Service Customer feedback
Background Fluorescence
Reject rate increased from 15% to 85% not practical.
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In conclusion:Flushing step not sufficiently robust.
No justification to modify the current procedure. As standard method meets SB requirement.
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 24
In-Service Customer feedback
Background Fluorescence
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In-Service Customer feedback
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 25
Suggestion to exploit the residual field, which is closeto the required field strength?
Variable in-service = no guarantee of sensitivity.
Residual field
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In-Service Customer feedback
Issues:Majority of yokes only work in AC.DC option not readily available. Achieving uniform and sufficient Field Strength challenging.
Conclusion: not able to recommend Magneticyokes
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 26
Use of Magnetic yokes?
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Content
Component: Thresholds and IntervalsProcedurePOD (Probability Of Detection)In-Service Customer feedbackConclusion
Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1 Page 27
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Conclusion
Key parameter detectable defect size .
Detectable Defect size determines threshold and interval.
Airbus procedures aim to be “fit for purpose”.
Increase sensitivity = raises reject rate.
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Conclusion
Operator Feedback:
Valued and productive.Positive effect on future procedures.
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Conclusion
Thank you for your FEEDBACK
Please continue.
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Semptember 2010 Rod Eye End Magnetic Partical Inspection In-Service Feedback - SEES7 - Ref. D27PR1013138 - Issue 1
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