Visit the Daimler Benz Aerospace NDI Laboratories in Bremen (DASA)
by Rolf Diederichs

The NDI Lab was introduced by Mr. Bisle, Mr. Schiller, Mr. Tober

1.
Ultrasonic crack inspection of joint panels with USIP-11. An A320 aircraft has about 300 meter long joint panels and the most critical sections have to be tested. In the first step an eddy current inspection checks the panels around holes on 6 mm long cracks. If cracks are present, ultrasonic testing with a 70° probe is used for further investigation and sizing of the cracks. The equipment used in the development of this procedure was as follows. USL48 from Krautkramer GmbH. Probe SMWB70-6, 70°, 6 MHz from Krautkramer. Accesories and ZG5 Couplant also from Krautkramer. Note: Any comparable ultrasonic equipment may be used provided that it satisfies the requirements of this procedure and is capable of resolving the reference slots in the reference standard at required level of resolution." The test was introduced by Mr. Steinberg and Mr. Scholz.

2.
This picture shows the test reference. The test is specified in part 4 "Ultrasonic Inspection for cracks in multi-layered joint structures" of the A319/A320/A312 NDT Manual. The procedure is applicable if the are to be inspected is of similar construction to that of figure 401.
Notice the three different artificial crack directions depicted on the reference surface.

3.
Possible damages are :
Fatique cracks > 4.5mm (0.177in) lenght in the multi-layered joint structure, starting at rivet holes in the covered skin layer and extending in the direction of the rivet row, with propagation through the whole thickness of the skin (Refer to figure 402).

4.
The inspection is carried out from outside or inside the aircraft; an illustration in the manual gives advice on how the search unit is to positioned and what scan movements must be performed by swivel scan to detect random angle cracks. (Refer to figure 408).

5.
Adjusting the Krautkramer USN 52 for lug testing. The lug of the horizontal stabilizer is tested by use of a 5 MHz angle beam probe. The probe's wedge was modified so that the contour of the specimen is matched.

6.
Testing of lugs performed with Krautkramer USN 52.

7.
Philips radioscopy of aircraft components. X-ray inspection is now a self-evident means of quality assurance in the fields of aviation and aerospace, both in production and general repair and maintenance. The great advances in aviation and aerospace would have been inconceivable if it had not been possible to conduct intensive non-destructive testing. Maximum safety is the essential need. In these important and exciting industries the full and proper inspection of welds, of castings and materials like glass or carbon fibre reinforced plastics, have become routine practices. An enormous volume of various components now undergoes full X-ray inspection - even during normal maintenance procedures.

8.
A new Shearography Method is investigated for detecting impact damages of the sensitive composite structure. The test was introduced by Mr. Scherling.

9.
By use of image postprocessing the results are clearly visible.

10.
An Ultrasonic System from Inspection Research Technology (IRT) is adapted to a large immersion tank. The use of ultrasonic c-scan systems and imaging software, ( Scan Master and upi-50 here) is an essential pre-condition for the examination of aircraft parts.

11.
Porosity is measured by evaluation of ultrasonic scattering. A new method which uses ultrasonic for investigation of porosity has been developed. Probes of 1.5 to 3 MHz are applied in through transmission and the backwall echo's frequency is evaluated with FFT. A FFT envelope of a good section and a section with porosity are compared and a relationship in the form of a "porosity figure" is found.
The test was introduced by Mr. Kück.

12.
A new automated eddy current system is investigated.

Contact
Daimler Benz Aerospace
Airbus GmbH
Hünefeldstraße 1-5
D-28199 Bremen
Phone +49 421 538-0
Fax +49 421 538-4180