CONTROL SHEET FOR PENETRANT, EMULSIFIER AND AMBIENT LIGHT (FORM-PT04) QUARTERLY CHECK

REFERENCE: PENETRANT PROCEDURE NO: VAECO.NDTP.PT01

Check Sensitivity First Quarter Second

Quarter Third Quarter Fourth Quarter

Penetrant Brightness

Level 2 Level 3 Level 4 Water Washable

Penetrant Removability

Level 3

Emulsifier Removability

Level 3 Level 4

Penetrant Brightness:

Brightness tests of in-use fluorescent penetrant shall be conducted at the intervals specified in Table 1. Tests shall be in accordance with the following method. Produce two 1% solutions of penetrant mixed with 99% acetone, one using standard unused penetrant, the other using penetrant from the process line under test. Using two pieces of filter paper, soak one in each of the prepared solutions and dry in an over circulating oven for five minutes at a temperature not exceeding 71° C. The intensity of the visible light emitted from the test sample is compared to that from the standard sample when both are excited by UV light from stabilised inspection lamp. If the variation of the emitted light intensity between the two test samples is greater than10%, the penetrant shall be rejected. The comparison is carried out by using a direct reading White Light Meter. The UV light intensity shall be the same one each sample and a minimum 1500 µWatts/cm² Position a white light meter directly under a stabilised UV lamp. Place one of the filter paper samples on the measuring lens of the meter such that it covers completely the light sensing area. After the reading, repeat the operation by substituting the other filter paper sample.

Water-Washable (Method A) Penetrant Removability:

When required in accordance with paragraph 4.3.7.8.3, the removability of water-washable (Method A) penetrant shall be tested using a specified test panel or any other commercially available grit blasted panel. The test shall be performed using a sample of unused penetrant serving as a reference. Place a streak of the unused reference sample on one portion of a panel and a separate streak of the in-use penetrant on a separate area of the panel. Allow the panel to drain for five minutes and then wash the panel using the temperature, pressure and wash times in use on the inspection line. Dry the panel, coat with developer, and examine under UV light. If the background of the in-use sample is visibly greater than that of the reference, then the in-use penetrant shall be discarded or otherwise corrected, as appropriate

Emulsifier Removability:

When required in accordance with paragraph 4.3.7.8.3, the removability of the in-use emulsifier shall be tested using an unused sample of the same brand of emulsifier serving as a reference. The test shall be conducted using two test panels and processing parameters specified in commercially available grit blasted panel. The in-use emulsifier shall be used with the unused penetrant on one panel and compared to the referenced system of unused emulsifier with unused penetrant on a second panel. Allow both the panels to drain for five minutes and then wash using the temperature, pressure and wash times used on the inspection line. Dry both panels, coat with developer, and examine under UV light. If the background is visibly greater than that of the reference system the emulsifier shall be discarded or otherwise corrected as appropriate.

Comparative Penetrant Sensitivity:

When required in accordance with paragraph 4.3.7.8.3, the comparative sensitivity of in-use penetrant shall be checked using the procedures in paragraph 4.3.7.8.3 except that the check shall be performed by comparing the in-use penetrant to the reference (hold-out) unused penetrant by processing both with unused emulsifier, if applicable, and unused developer. If the comparative sensitivity of the in-use penetrant is noticeable less than the reference penetrant, the in-use penetrant is unsatisfactory for use.

Inspection Area:

The inspection area for stationary systems for Type 1 penetrants shall be checked as specified in Table 1 and shall be clean and free from excessive fluorescent contaminations and excessive visible light background. The ambient visible light background shall be checked at intervals specified in Table 1 or when any changes, or constructions, or both, in the inspection area are made. Ambient visible light shall not exceed 5 lux at the examination surface.

Issue: 02, Revision: 00, Date: 15 Dec. 2011 Page 4-54

4.4 WRITTEN INSTRUCTIONS FOR PT METHOD 4.4.1 Use of Colour Contrast Penetrant

THIS INSTRUCTION DOES NOT HAVE PRECEDENCE OVER OEM OR MANUFACTURER’S NDT MANUAL AND INSTRUCTIONS

Personnel carrying out this inspection shall be qualified as PT Level 1 or Level 2 in accordance with Part 3 of the NDT Manual

Type II, Method C, Form d

Not Approved for Aircraft parts inspection Reference:

 ASTM E1417 Materials

 Pre-cleaner ARDROX 20% or approved non residue oil free cleaner

 Penetrant DP-40 or its equivalent

 Remover DR-60 or its equivalent

 Developer D-100 or its equivalent

 Only products qualified under AMS 2644 shall be used

 Penetrants shall not be mixed from different manufacturers or families without authority of the Level 3 (if an AOG situation exists).

Procedure 1. PRE-CLEAN

Remove paint, corrosion and surface scale as required. Wipe with solvent-dampened lint-free cloth, followed by a clean lint-lint-free cloth.

2. PENETRANT APPLICATION PRE-CLEAN

Spray on penetrant. Contact time 20 min. If penetrant dries, re-process from step 2.

3. EXCESS PENETRANT REMOVAL

Wipe with dry cloth followed by solvent-dampened free cloth, followed by a clean lint-free cloth.

4. DEVELOPER APPLICATION:

Apply developer to give a thin uniform film, just sufficient to obscure specimen surface.

Minimum contact time shall be 10 minutes.

5. INSPECTION

Immediately after developer application, and at intervals until the developer time of at least 10 minutes has elapsed. Inspection is to be assisted by X3 to X10 magnification.

6. ILLUMINATION

White light intensity is to be greater than 1000 lux at inspection surface 7. EVALUATION

All indications shall be evaluated as:

a) relevant b) non-relevant c) spurious (false)

Evaluation shall be accomplished by wiping each indication with a single wipe using a solvent moistened swab. If the indication does not reappear immediately solvent developer shall be applied on suspect area in a light coating. After 10 minutes the

suspect area shall be re-inspected. If the indication reappears it shall be considered relevant, unless caused by a geometrical reservoir of penetrant evident on all parts of the same part no. All relevant indications exceeding 1 mm after bleedout shall be further evaluated against the customer specification or original equipment manufacturer reject criteria.

8. POST-EXAMINATION CLEANING : Remove all traces of Penetrant and developer using approved solvent cleaner.

Issue: 02, Revision: 00, Date: 15 Dec. 2011 Page 4-56

4.4.2 POST EMULSIFIED FLUORESCENT INSPECTION OF AIRCRAFT PARTS

THIS INSTRUCTION DOES NOT HAVE PRECEDENCE OVER OEM OR MANUFACTURER’S NDT MANUAL AND INSTRUCTIONS.

Personnel carrying out this inspection shall be qualified as PT Level 1 or Level 2 in accordance with Part 3 of the NDT Manual .

Type 1, Method D, Form a

Approved for aircraft parts inspection Reference

 ASTM E1417

Materials

 Pre-cleaner ARDROX 20% or approved non residue oil free cleaner

 Penetrant : RC77 Sensitivity Level 4 or its equivalent

 Emusifier : ER-83A or its equivalent

 Developer: D-90G or its equivalent

 Only products qualified under AMS 2644 shall be used

 Penetrants shall not be mixed from different manufacturers or families without authority of the Level 3 (if an AOG situation exists).

Procedure

1. TEMPERATURE CONTROL

Excluding pre-cleaning and post-cleaning operations, component and material

temperature shall remain within the limits of 4 to 52 degrees centigrade unless otherwise specified.

2. PRE-CLEAN

Prior to inspection, ensure production parts have been processed in accordance with Boeing SOPM 20-30-03 and are protected from corrosion by covering with protective paper. Immediately prior to penetrant application uncover and wipe with solvent-dampened nap-free cloth or tissue, followed by a clean dry cloth or tissue.

3. PENETRANT APPLICATION

Apply by immersion or spray and allow to drain. Immersion time is not to be less than 2 minutes or exceed 10 minutes. Dwell time shall be 20 minutes minimum. If Penetrant dries, re-process from step 1.

4. PRE-RINSE

Remove excess penetrant by water spray wash, monitored under UV-A lamp at 100 µW/cm² minimum with a maximum of 10fc ( 107.6 lx ) of ambient visible light at the part surface.

Water pressure 40 psi (2.7 bar) maximum Water temperature 10 - 38 °C

Spray nozzle is to be greater than (12”) 305 mm away from surface at an angle of 45°

5. EMULSIFICATION

Confirm the emulsifier concentration is in limits 8-10%. Immerse in the emulsifier and lightly agitate for a period as listed on the attached Table. Emulsification time shall be from immersion to the point of spray removal.

6. SPRAY REMOVAL

Remove excess penetrant and emulsifier by water spray wash, monitored under UV-A lamp at 100 µW/cm² minimum with a maximum of 10fc ( 107.6 lx ) of ambient visible light at the part surface.

Water pressure 40 psi (2.7 bar) maximum Water temperature 10 - 38 °C

Spray nozzle is to be greater than (12”) 305 mm away from surface at an angle of 45°

7. DRYING

Dry in hot air oven, oven temperature 70°C / 158°F, until dry (preferable temperature is 50°C / 122°F)

8. DEVELOPER APPLICATION

Apply Non-aqueous developer. Minimum contact time shall be 10 minutes, maximum 30 minutes.

9. INSPECTION

Immediately after developer application, and at intervals until the developer time of at least 10 minutes has elapsed. Inspection is to be assisted by X5 to X10 magnification.

10. EVALUATION

All indications shall be evaluated as:

a) relevant b) non-relevant c) spurious (false)

Evaluation shall be accomplished wearing UV spectacles by wiping each indication with a single wipe using a solvent moistened swab. If the indication does not reappear

immediately solvent developer shall be applied on suspect area in a light coating. After 10 minutes and before 30 minutes has elapsed, the suspect area shall be re-inspected. If the indication reappears it shall be considered relevant, unless caused by a geometrical reservoir of penetrant evident on all parts of the same part no. All relevant indications exceeding 1 mm after bleedout shall be further evaluated by the Level 2 against the customer specification or original equipment manufacturer reject criteria using X10 magnification under white light. Measurement shall be accomplished by use of an optical graticule.

11. ILLUMINATION

UV-A light intensity is to be greater than 1500 µW/cm², at inspection surface.

White light intensity is to be less than 20 lux at inspection surface 12. POST-EXAMINATION CLEANING

Issue: 02, Revision: 00, Date: 15 Dec. 2011 Page 4-58

Immediately protect from corrosion by wrapping or covering with protective paper.

Forward for Boeing SOPM 20-30-03 process cleaning 13. PROTECTION

Reapply surface protection as required.