NDT Manual Aescpdf PDF

NON DESTRUCTIVE TESTING MANUAL
NON DESTRUCTIVE
TESTING MANUAL
DOCUMENT No: AESC/NDT/MANUAL/002
Revision: 02
Issue Date: Apr,2012
Ha Noi Main Facility (MT1) Ho Chi Minh Branch (MT2)
Lot 43A, Quang Minh Industrial Zone, Me Linh, Ha Noi, Viet Nam E917, Tan Son Nhat
Tel: (84)-4-38185930 InternationalAirport, HCM City.
Fax: (84)-4-38185931 Tel: (84)-8-6 6751341
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PART 1-GENERAL
PART 1
GENERAL
Page 1-1
AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012
PART 1-GENERAL
1.1 TABLE OF CONTENTS

PART 1 GENERAL.......................................................................................................... 1-1
1.1 TABLE OF CONTENTS ..................................................................................... 1-2
1.2 RECORD OF REVISIONS ................................................................................. 1-3
1.3 SUMMARY OF AMENDMENT …………………………………… 1-4
1.4 DISTRIBUTION LIST ........................................................................................ 1-5
1.5 ABBREVIATION................................................................................................. 1-5
1.6 LIST OF EFFECTIVE PAGES ………………………………………. 1-6
1.7 REVISION PROCEDURE .................................................................................. 1-9
PART 2 MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION ...................... 2-1
2.1 GENERAL .......................................................................................................... 2-2
2.2 APPLICABLE NDT METHODS ..................................................................... 2-2
2.3 NDT FACILITIES.............................................................................................. 2-3
2.4 PRIVILEGES OF NDT STAFF ........................................................................ 2-6
2.5 EQUIVALENT ASSESSMENT OF NDT EQUIPMENT
AND MANUFACTURE STANDARD BLOCK ............................................ 2-8
PART 3 WRITTEN PRACTICE ......................................................................................... 3-1
3.1 SCOPE............................................................................................................... 3-2
3.2 NORMATIVE REFERENCES ......................................................................... 3-3
3.3 TERMS AND DEFINITIONS ......................................................................... 3-3
3.4 GENERAL REQUIREMENTS ......................................................................... 3-6
3.5 QUALIFICATION AND CERTIFICATION LEVELS .................................... 3-8
3.6 TRAINING AND EXPERIENCE ..................................................................... 3-10
3.7 EXAMINATIONS ............................................................................................. 3-14
3.8 CERTIFICATION.............................................................................................. 3-18
PART 4 NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS ....................... ….4-1
4.1 EDDY CURRENT INSPECTION PROCEDURE........................................... 4-2
4.2 MAGNETIC PARTICLE INSPECTION PROCEDURE................................ 4-6
4.3 PENETRANT INSPECTION PROCEDURE ................................................. 4-31
4.4 ULTRASONIC INSPECTION PROCEDURE ............................................... 4-50
4.5 EDDY CURRENT INSPECTION INSTRUCTION ………………….. 4-54
4.6 MAGNETIC INSPECTION INSTRUCTION ……………………… 4-61
4.7 PENETRANT INSPECTION INSTRUCTION ........................................... 4-65
4.8 ULTRASONIC INSPECTION INSTRUCTION ........................................... 4-74
Page 1-2
PART1-GENERAL
1.2 RECORD OF REVISIONS
Revision No Revision Date Revision Reason Remark
00 Nov,2008 Original Issuance
01 Jun,2010 Revised and additional
02 Apr,2012 Revised
Page 1-3
PART1-GENERAL
1.3 SUMMARY OF AMENDMENT

The following table shows the summary of the latest amendment of the AESC NDTM.
Manual Name : Non Destructive Testing Manual
Manual Code : AESC NDTM
Issue Number : 002
Revision Number : 02
Part Removed Pages Inserted Pages Reason For Amendment

1-4 All All Content changes
This page is updated whenever there is any amendment.

The Quality Assurance Department keeps all revision information.
Page 1-4
PART1-GENERAL
1.4 DITRIBUTION
The NDT Manual is approved by the NDT Level3.
The manual shall be distributed by the Shop Supervisor after acceptance to the assigned holder.
The manual holder is responsible for inserting and recording the revised pages in their manual.
1.5 ABBREVIATION
Abbreviation used in the NDTM are listed in the following table:
No ABBREVIATION MEANING
1 NDTM Non Destructive Testing Manual
2 NDT Non Destructive Testing
3 ET Eddy Current Testing
4 MT Magnetic Particle Testing
5 PT Penetrant Testing
6 UT Ultrasonic Testing
7 AESC Aerospace Engineering Service Joint Stock Company
This table of abbreviation will be updated if any abbreviation used.
Page 1-5
PART1-GENERAL
1.6 LIST OF EFFECTIVE PAGES

1. The pages listed here are identified in the format of: Chapter Number - Page
Number.
2. The Revision Date here is identified in the format of: dd mmm. yyyy.
Pages Issue Revision Revision Date Pages Issue Revision Revision Date
1-1 002 02 Apr 2012 3-11 002 02 Apr 2012
1-2 002 02 Apr 2012 3-12 002 02 Apr 2012
1-3 002 02 Apr 2012 3-13 002 02 Apr 2012
1-4 002 02 Apr 2012 3-14 002 02 Apr 2012
1-5 002 02 Apr 2012 3-15 002 02 Apr 2012
1-6 002 02 Apr 2012 3-16 002 02 Apr 2012
1-7 002 02 Apr 2012 3-17 002 02 Apr 2012
1-8 002 02 Apr 2012 3-18 002 02 Apr 2012
1-9 002 02 Apr 2012 3-19 002 02 Apr 2012
2-1 002 02 Apr 2012 3-20 002 02 Apr 2012
2-2 002 02 Apr 2012 3-21 002 02 Apr 2012
2-3 002 02 Apr 2012 3-22 002 02 Apr 2012
2-4 002 02 Apr 2012 3-23 002 02 Apr 2012
2-5 002 02 Apr 2012 3-24 002 02 Apr 2012
2-6 002 02 Apr 2012 3-25 002 02 Apr 2012
2-7 002 02 Apr 2012 3-26 002 02 Apr 2012
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4-80 002 02 LEVEL 3
RESPONSIBLE QUALITY ASSURANCE DIRECTOR
Date of Approval: April 2012 Date of Review: April 2012
Truong Thanh Chung Mai The Chien
Page 1-8
PART1-GENERAL
1.7 REVISION PROCEDURE

1. The NDT Manual is revised on an as-needed basis.
2. Gathering information and preparing revised pages:
a. Revisions to the NDT Manual may be resulted from:
Requests for quality or procedural improvements;
Regulatory requirement or guidance changes;
Changes in policies or procedures that affect NDT activities;
Feedback from employees or customers regarding improvements;
Authority audits, quality audits or inspector reports;
Any other request that may affect NDT activities.
3. Review and submit for approval:

a. The revised pages of the NDT Manual will be submitted to the Quality
Assurance Director for review of the revised content before being sent to the
Responsible Level 3 for approval.
Page 1-9
PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION
PART 2
MANAGEMENT, FACILITIES &
PERSONNEL QUALIFICATION
AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012 Page 2-1

2.1 GENERAL
1. AESC has two NDT shops, one belongs to the HAN ( MT1) and the other
belongs to the HCM (MT2). The NDT shops are major supporting shops for the
maintenance tasks performed in AESC. The role of the NDT shops is to provide
NDT inspection to aircrafts, and parts in accordance with manufacturer’s or
regulatory specifications.
2. The AESC NDT shops comply with EN 4179 and NAS 410 for the
qualification and approval of NDT personnel.
3. The AESC NDT shops shall follow manufacturer’s procedures when provided
and strictly obey the NDT written instructions approved by the Responsible Level
3 described in this manual when no manufacturer procedures are available.
4. AESC has appointed an external Responsible Level 3 who is responsible for the
technical supervision of NDT and the internal/ external audit functions.
2.2 APPLICABLE NDT METHODS
AESC NDT shops have the capability to perform NDT inspections using the
following methods:
1. Penetrant Testing (PT)
2. Magnetic Particle Testing (MT)
3. Eddy Current Testing (ET)
4. Ultrasonic Testing (UT)

2.3 NDT FACILITIES

2.3.1 HAN NDT Shop Facilities
2.3.1.1 HAN NDT Shop Layout

2.3.1.2 NDT Equipment

The main NDT equipment of the HAN NDT shop consists of:
1. Magnetic Particle Test Bench
2. Penetrant Station.
3. Eddy current equipment
4. Calibration standards
5. Probes
6. Yoke

2.3.1.3 NDT FACILITIES

2.3.1.4 HCM NDT Shop Facilities
2.3.1.5 HCM NDT Shop Layout
Page 2-5
2.3.2 NDT Equipment

The main NDT equipment of the HCM NDT shop consists of:
1. Ultrasonic equipment.
2. Calibration standards
3. Probes and accessories
4. Eddy current equipment
5. Joke
2.4 PRIVILEGES OF NDT STAFF

2.4.1.1 Level 1
In the method in which authorized, Level 1 staff are permitted to:
1. Process parts, document results and perform equipment standardization in

accordance with approved work instructions.
2. Carry out the necessary preparation of parts before or after inspection in
accordance with approved work instructions.
3. Conduct system performance checks in accordance with the applicable process
standard.
4. Carry out NDT inspections when provided with a Level 3 approved
instructions or being directly supervised by a Level 2 authorized in the method.
2.4.1.2 Level 2
1. Set up and standardize equipment, process parts, interpret and evaluate for
acceptance or rejection, and document results.
2. Conduct system performance checks in accordance with the applicable process
standard.
3. Provide the necessary guidance and/or supervision to trainees and Level 1
personnel.
4. Develop work instructions from approved general procedures. However, such
instructions shall require final approval by a Level 3 authorized in the method
Page 2-6
2.4.1.3 Level 3
1. Interpret codes, standards, and other contractual documents that control the
NDT method(s) used by AESC
2. Select the method and technique for a specific inspection.
3. Prepare and verify the adequacy of procedures and work instructions.
4. Approve NDT procedures and other NDT-related work instruction for
technical adequacy
5. Provide or direct training, examination, and certification of NDT personnel.
2.4.1.4 Responsible Level 3
In addition to the privileges of the Level 3 staff mentioned above, the Responsible
Level 3 also has the following privileges:
1. Approve, implement the Written Practice and do the overall administration of the
NDT qualification and certification program.
2. Do the overall administration of the NDT Shops, establish policy, procedure and
programs related to NDT.
3. Carry out internal audits and/or outside agency audits to ensure the
necessary requirements are met.
2.4.1.5 NDT Auditors
NDT Auditors, who is nominated by the Quality Director, are permitted to perform:
1. Internal audits related to NDT following instructions issued by the
responsible Level 3.
2. External supplier technical NDT audits, surveys or assessments.
Page 2-7
2.5 EQUIVALENT ASSESSMENT OF NDT EQUIPMENT AND MANUFACTURE

STANDARD BLOCK
1. NDT equipment can be varied to suit the available equipment and Aircraft
configuration. However, any such changes must still guarantee the same level of
defect detection as the original procedures.
2. Where the manufacturer/OEM details specific equipments to be used for NDT
tasks by manufacturer and part number, the use of equivalent equipment (tool,
standard, probe, cable...) for a NDT task has to be permitted/approved by
the NDT Level 3
3. A NDT Level 2 can only assess equivalent equipment for UT and ET (where the
NDT task allows substitute equipment), the assessment is recorded in the NDT
REPORT The equivalency is normally demonstrated by the screen signal from the
conforming NDT calibration reference block(s) being presented on the
instrument and matching as shown in the NDT task.
4. In general, only aircraft manufacture’s NDT calibration blocks can be used.
In some cases, where detailed drawings are provided by A/C manufacture or any
OEM, it is permissible for AESC to manufacture its own NDT calibration
blocks. For reasons of audit and traceability, NDT calibration blocks produced by
AESC or manufacturing contractor should have a C of C or equivalent certified
document, with a part number and serial number shown. These blocks should
be tested and certified by a NDT level II (minimum) to show that the
block is fit for purpose
Page 2-8
PART 3- WRITTEN PRACTICE – AESC/NDT/WP02
PART 3
WRITTEN PRACTICE
Page 3-1
3.1 SCOPE
3.1.1 Purpose
1. This document is the written procedure (written practice) for the Qualification and
Certification of NDT personnel of AESC. The document meets or exceeds the
minimum requirements for the qualification and certification of personnel
involved in the application of non-destructive testing (NDT) in accordance with
EN4179:2009 and NAS 410 Issue 3 March 2008.
2. Except when otherwise specified in the written practice, certification includes
operating approval.
3.1.1.1 Responsible Level 3
AESC has appointed an external Responsible Level 3 in accordance with the
requirements of EASA FAR Part 145. The Responsible Level 3 is responsible to the AESC
Quality Assurance Director for the technical supervision of NDT.
3.1.2 Applicability
1. This document applies to personnel using NDT methods to test and/or
accept materials, products, components, assemblies or sub-
assemblies. It also applies to those individuals directly responsible for the
technical adequacy of the NDT methods used, as well as personnel performing
external NDT technical audits or providing technical NDT training.
2. This document is not intended to apply to individuals who only have
administrative authority over the personnel identified above, nor does it
apply to research personnel developing technology for subsequent approval by a
certified Level 3.
3. Personnel performing specialized inspections using certain direct readout
instruments as determined by a Level 3 certified in the method do not
require qualification or certification to this document.
3.1.3 Implementation
Personnel certified to previous revisions of the AESC Written Practice do not need to
recertify to the requirements of this document until their current certification expires.
3.1.4 Common methods
The NDT methods used are: Penetrant, Magnetic Particle, Eddy Current, Ultrasonic,
Radiography, Visual, Thermography and Hardness Testing.
3.1.5 Other methods
When invoked by engineering, quality, cognizant engineering organisation or prime
contractor requirements, this procedure applies to other current and emerging NDT
methods used to determine the acceptability or suitability for intended service of a
material, part, component, sub-assembly or assembly. Such methods may include, but
are not limited to, acoustic emission, neutron radiography, leak testing and holograpy.
The requirements for personnel training, experience and examination for these other
methods shall be established in accordance with paragraph 3.6.4 and documented by
AESC.
Page 3-2
3.2 NORMATIVE REFERENCES

3.2.1 Standards
The current revisions of the following documents as of the date of this document were
used as the foundation for this document:
1. EN4179:2009 Aerospace Series - Qualification and Approval of Personnel for
Non-destructive Testing.
3.2.2 Order of Precedence

In the event of a conflict between the text of this document, EN 4179:2009 and the
references , the requirements of EN 4179:2009 take precedence. Nothing in this
document or EN 4179:2009 supersedes applicable laws and regulations unless a
specific exemption has been obtained.
3.3 TERMS AND DEFINITIONS
For the purposes of this document the following terms and definitions apply.
3.3.1 Certification:
A written statement by an employer that an individual has met the applicable
requirements of this standard.
3.3.2 Closed book examination:
An examination administered without access to any reference materials.
3.3.3 Cognizant engineering organization:
The engineering or NDT organization of the prime contractor or end user authorized to
make NDT-related decisions and give NDT-related approvals.
3.3.4 Direct observation:
Direct observation is when the observer is able to come to the immediate aid of the
trainee and remains within a distance that permits uninterrupted, unaided visual and
verbal contact with the trainee.
3.3.5 Direct readout instrument:
Instruments that physically display measurements in dimensional or electrical units
(e.g. inches, millimeters or %IACS, etc.) either as digital readout or an analog display,
such as a scale/pointer configuration and do not require special skills or knowledge to
set up the instrument and do not involve adjusting signal displays such as gates,
delays, gain, or phase to obtain measurements. For example, common direct readout
instruments include basic ultrasonic thickness gauges without an oscilloscope display,
and eddy current coating thickness gauges.
3.3.6 Documented:
The condition of being recorded in written or electronic form.
Page 3-3
3.3.7 Employer:
A government, prime contractor, sub-contractor, supplier, or outside agency
employing or contracting the services of one or more individuals who perform
NDT. Self-employed individuals are included in this definition.
3.3.8 Evaluation:
A review following interpretation of the indications noted during an NDT
inspection to determine whether the indications meet specified acceptance criteria
or to determine the significance of the indication.
3.3.9 Examination:
Formal, controlled, documented testing conducted in accordance with a documented
written practice to verify a candidate's visual capability, skill or knowledge of an NDT
method.
3.3.10 Examiner:
A Level 3 certified to this standard and designated by the Responsible Level 3 or
NANDTB to administer all or part of the qualification and certification process,
excluding vision examinations, in the NDT method(s) in which the Examiner is
certified.
3.3.11 Experience:
Actual performance of an NDT method conducted in the work environment resulting
in the acquisition of knowledge and skill. This does not include formal classroom
training, but may include laboratory and on-the-job training as defined by the
employer's written practice.
3.3.12 Formal training:
An organized and documented program of learning activities designed to impart the
knowledge and skills necessary to be qualified to this standard. Formal training
may be a mix of classroom, practical and programmed self-instruction as approved by
the Responsible Level 3, Examiner or, NANDTB.
3.3.13 General examination:
A written examination addressing the basic principles and theory of an NDT
method.
3.3.14 Indication:
The response or evidence of a condition resulting from an NDT inspection that requires
interpretation to determine its significance.
3.3.15 Instructor:
An individual designated or approved by the Responsible Level 3 or NANDTB to
provide training for NDT personnel.
3.3.16 Interpretation:
The determination of whether indications are relevant or non-relevant.
3.3.17 Method:
One of the disciplines of non-destructive testing (e.g. ultrasonic, radiography, etc)
within which different techniques may exist.
Page 3-4
3.3.18 National Aerospace NDT Board (NANDTB):

An independent national aerospace organization representing a nation's aerospace
industry that is chartered by the participating prime contractors and recognized by
the nation's regulatory agencies to provide or support NDT qualification, examination,
and/or certification services in accordance with this standard.
3.3.19 On-the-job training:
Training in the work environment to gain experience in learning instrument set- up,
equipment operation, applying the process, and recognition, interpretation and
evaluation of indications under appropriate technical guidance.
3.3.20 Open book examination:
An examination administered with access to specific reference material that is
provided with or referenced in the examination.
3.3.21 Operating approval:
Written statement issued by the employer, based upon the scope of certification,
authorizing the individual to carry out defined tasks. Such authorization can be
dependent on the employer having provided job or task-specific training.
3.3.22 Outside agency:
An independent company or organization outside the employer who provides NDT
services to implement the requirements of this standard, such as training and
examination of NDT personnel.
3.3.23 Practical examination:
An examination to demonstrate an individual's ability to conduct an NDT method as
used by the employer. Questions and answers need not be written, but a checklist
must be used and observations and results must be documented.
3.3.24 Prime contractor:
An organization having overall responsibility for design, control and delivery of a
system, component or product.
3.3.25 Procedure:
A written general "how to" instruction for conducting a given process. Procedures are
then used to develop work instructions, as defined in 3.3.32.
3.3.26 Qualification:
The skills, training, knowledge, examinations, experience and visual capability required
for personnel to properly perform to a particular level.
3.3.27 Responsible level 3:
A Level 3 designated by the employer with the responsibility and authority to ensure
that the requirements of this standard are met and to act on behalf of the employer.
3.3.28 Specific examination:
A written examination to determine an individual's understanding of operating
procedures, codes, standards, product technology, test techniques, equipment and
specifications for an NDT method as used by the employer.
Page 3-5
3.3.29 Sub-contractor:
An organization responsible to the prime contractor for the manufacture or
maintenance of aerospace products. For the purposes of this standard, this includes
suppliers and processors.
3.3.30 Technique:
A category within a method; for example, ultrasonic immersion testing or
ultrasonic testing of composites. Specific techniques within a method are defined by
the employer or NANDTB.
3.3.31 Test sample:
A part or image containing one or more known and documented natural or
artificial discontinuities, flaws or conditions used in the practical examination to
demonstrate the candidate's proficiency in an NDT method. Test samples can
refer to actual hardware, fabricated test parts, or, when applicable, images of actual
hardware such as radiographs.
3.3.32 Work instruction:
A document detailing the NDT technique and testing parameters to be used for the
inspection of a specific component, group of parts (e.g. "aluminium extrusions"
or "steel brackets"), or assembly. These are sometimes referred to in the industry as
"technique sheets" or "data cards". Such 'work instructions are based on procedures
defined in 3.3.25.
3.3.33 Written:
Retrievable electronic or hard copy.
3.3.34 Written practice:
A procedure that describes an employer's requirements and methodology for
controlling and administering the NDT personnel qualification and certification
process.
3.4 GENERAL REQUIREMENTS
3.4.1 Written Practice
This Written Practice has been developed in accordance with EN4179:2009 (which is
equivalent in technical content to AIA NAS 410:2008) and includes the following
requirements:
1. Levels of qualification
2. Personnel duties and responsibilities
3. Training programme
4. Experience requirements
5. Examination practices
6. Records and administration
7. Recertification requirements
3.4.1.1 Additional requirements
Not applicable
Page 3-6
3.4.1.2 NDT Techniques

The following specific techniques used are:
1. Penetrant – Fluorescent – Water Washable
2. Penetrant – Fluorescent – Solvent Removable
3. Magnetic Particle – Fluorescent – Stationary bench
4. Magnetic Particle – Fluorescent - Yoke
5. Eddy Current – High Frequency
6. Eddy Current – Low Frequency
7. Ultrasonic – Compressional Wave
8. Ultrasonic – Shear Wave
9. Ultrasonic – Resonance Bond Testing
3.4.1.3 Training Outlines

1. The NDT Training Outlines are included as Appendix B to this procedure.
2. The Responsible Level 3 shall verify that the Outside Agency providing the
training meets the company requirements.
3.4.1.4 Examination Practices
Aerospace Inspection Training Ltd is the Outside Agency responsible for administering
examinations. The examination requirements are detailed in paragraph 7 -
Examinations. The specific visual examination method is detailed in Table 5 – Vision
Requirements.
3.4.1.5 Administration
The Responsible Level 3 identified in Appendix A is responsible for administering and
maintaining the certification program of AESC.
3.4.1.6 Records
The AESC Quality Director is responsible for maintaining the qualification and
certification records.
3.4.2 Methods
For the methods listed in paragraph 3.1.4 of this document, the requirements for
training, experience and examination are detailed in paragraphs 6 and 7 of this
procedure.
3.4.3 Level 1-Limited
Level 1 Limited is suitable for AESC .
3.4.4 Responsibility
1. AESC is responsible for implementation of, and compliance with, this written
practice and for certifying qualified personnel. AESC uses an
Page 3-7
Outside Agency for training and examining their personnel and performing other Level
3 functions as appropriate.AESC is responsible for assuring that the appropriate
requirements of the Written Practice are met by documenting the suitability of the
Outside Agency and identifying in writing the name of the Responsible Level 3 from
the Outside Agency who is Level3 certified.
2. The Outside Agency and Responsible Level 3 is identified in Appendix A.
3. AESC is solely responsible for the certification of its employees and cannot certify
for another employer.
3.4.5 Responsible Level 3
1. The Responsible Level 3 shall be:
a. certified in accordance with EN4179:2009 as a Level 3 in one ore more
NDT methods;
b. have have a thorough knowledge of the written instrcuctions, codes,
specifications and standards used by AESC;
c. have a thorough knowledge of the materials, components, product
technologies, NDT methods and NDT techniques used by AESC.
2. The Responsible Level 3 shall approve any NDT certification by AESC.
3. The Responsible Level 3 having responsibility for the implementation of the
Written Practice and overall administration of the qualification and
certification program is identified in Appendix A.
4. The designated Level 3 Examiners are identified in Appendix A.
3.4.6 Outside Agency
1. The functions of the Outside Agency are:
a. to develop a certification program
b. to act as the Responsible Level
c. to examine NDT personnel
d. to perform any other qualification Level 3 function
2. AESC shall document the suitability of the Outside Agency to perform any
function in meeting the requirements of the Written Practice. The documentation
shall be of sufficient detail to justify the Outside Agency’s ability to perform the
required Level 3 function(s).
3.5 QUALIFICATION AND CERTIFICATION LEVELS
3.5.1 Levels of Qualification and Certification
1. AESC uses three levels of certification:
a. Level 1
b. Level 2
c. Level 3
2. NDT Personnel shall not independently perform the functions listed below if not
certified to the appropriate level in the applicable technique/method.
Page 3-8
3.5.1.1 Trainee
A trainee is an individual who is participating in a training program for an NDT
method and is in the process of becoming qualified for certification.
In the technique/method in which they are preparing for certification, trainees
shall:
1. be documented as a trainee and be actively participating in a training
program for a stated NDT method for a limited and specified period of time;
2. obtain experience under the direct observation of a Level 2 or Level 3 in the same
method;
3. obtain experience under the direct observation of a Level 1 or Instructor only
when approved by the Responsible Level 3;
4. not make accept or reject decisions;
5. not independently conduct tests;
6. not independently perform any other NDT function.
3.5.1.2 Level 1
In the method in which certified, Level1 individuals shall:
1. be able to follow work instructions;
2. have the skills and knowledge to process parts, document results and
perform equipment standardization in accordance with approved work
instructions;
3. have the skills and knowledge to carry out any necessary preparation of parts
before or after inspection in accordance with approved work instructions;
4. have the skills and knowledge to conduct system performance checks in
accordance with the applicable process standard;
5. receive guidance or supervision from a certified Level 2 or Level 3 in that
method when necessary;
6. only be approved for carrying out NDT inspections when provided with a
Level 3 approved instruction or be directly supervised by a Level 2.
3.5.1.3 Level 2
In the method in which certified, the Level 2 individuals shall:
1. have the skills and knowledge to set up and standardise equipment, process parts,
interpret and evaluate for acceptance or rejection, and document results;
2. be thoroughly familiar with the scope and limitations of the
technique/method;
3. have the skills and knowledge to conduct system performance checks in
accordance with the applicable process standard;
4. be capable of providing the necessary guidance and/or supervision to
trainees and Level 1 personnel;
5. be familiar with the codes, standards, and other contractual documents that
control the method as utilized by AESC;
Page 3-9
6. have a basic knowledge of relevant product manufacturing and inspection

technology;
7. be capable of developing work instructions from approved general
procedures. AESC approves the Level 2 to develop work instructions, however
such work instructions shall require final approval by a Level 3 certified in the
method;
3.5.1.4 Level 3
In the method in which certified, the Level 3 individuals shall:
1. have the skills and knowledge to interpret codes, standards, and other
contractual documents that control the NDT method(s) used by AESC;
2. be capable of assuming technical responsibility for the NDT facility and staff;
3. be capable of selecting the method and technique for a specific inspection;
4. be capable of preparing and verifying the adequacy of procedures and work
instructions;
5. approve NDT procedures and other NDT-related work instruction for
technical adequacy;
6. have a general knowledge of other NDT methods and product manufacturing and
inspection technologies used by AESC
7. be capable of providing or directing training, examination, and certification of
personnel;
8. conduct NDT for the acceptance of parts and document the results if a
demonstration of proficiency in this ability was included in the practical
examination.
3.6 TRAINING AND EXPERIENCE
3.6.1 Training
1. Candidates for certification to all levels shall complete sufficient organised
training to become proficient with the principles and practices of the applicable
test method and technique(s) and be capable of carrying out the duties specified
in Paragraph 3.5.
2. Formal training shall be conducted prior to, or in conjunction with, on-the-job
training. All NDT training shall be documented.
3. The minimum training hours for Levels 1 and 2 are provided in Table 1 for the
specified NDT methods.
4. Individuals cannot certify to Level 3 without prior certification to Level 2 or
performance equivalent to a Level 2 except in accordance with Paragraph
3.6.4
5. General, specific and practical training may be obtained with AESC or Outside
Agency but shall always be supplemented by on-the-job training with AESC.
Page 3-10
Table 1 - Minimum Formal Training Hours, Levels 1 and 2
Method Level 1 Level 2 Level 2

with Level 1 without Level 1
PT 16 16
certification 32
certification
MT 16 16 32
ET 40 40 80
UT 40 40 80
RT 40 40 80
VT 8 16 24
TT 20 40 60
HT - 8 8
3.6.1.1 Training Outlines
1. All training shall be conducted in accordance with a detailed course outline
approved by the Responsible Level 3. The outline shall include a list of references
from which the training material is derived. As a minimum the training shall
include:
a. Basic theory;
b. Test Principles, including choice of NDT methods, relevance to different
materials and part and test variables;
c. Product forms and materials; defect formation and characterization;
d. Equipment operation and standardization;
e. The importance of process controls;
f. The importance of appropriate processing steps and parameters;
g. Safety;
h. Applicable techniques and the advantages and disadvantages of each;
i. Limitations and capabilities of each method and technique;
j. Applicable specifications, codes, operating procedures and work
instructions;
k. If applicable, evaluation, interpretation and documentation of inspection
results.
2. The Responsible Level 3 shall verify that the training provided by the
Outside Agency meets the requirements of AESC.
3.6.1.2 Previous Training

For personnel credited with previous training or personnel not certified within 12
months of their training, refresher training must be provided. Previous training must be
documented to be accepted by AESC. At a minimum, refresher training shall cover:
1. products
2. equipment set-up,

3. operation and standardization,

4. specific operating procedures,
5. applicable techniques,
6. interpretation and evaluation of NDT results,
7. safety, and
8. applicable codes, standards and specifications.
3.6.1.3 Equivalent training
For personnel previously certified under NAS 410, EN4179 or other recognised NDT
qualification program, the adequacy and equivalency of their previous training to the
requirements of Table 1 shall be determined and documented by the Responsible
Level 3.
3.6.1.4 Health and safety training
All regulations relating to hazardous substances, accident prevention and safe
working practices shall be strictly adhered to. Safety-related training requirements shall
be determined by AESC in accordance with local codes and regulations. Prior to
certification, all candidates seeking radiography qualification shall have received
instruction on the hazards and safety requirements associated with ionizing radiation
and are knowledgeable of, and comply with, the applicable regulations and laws.
3.6.1.5 Training facilities
1. Training facilities and classrooms shall provide and environment conducive to
learning and shall be sufficiently well equipped with training aids, models,
samples, etc., to ensure that all aspects of the training course requirements are
met. In addition, a sufficient number of representative test samples containing
natural or artificial features and/or flaws shall be available to cover the range
of testing to be conducted by the candidate.
2. Test samples used for practical examinations shall not be used for training
purposes.
3. To ensure the candidate fully benefits from the practical exercises,
equipment used for training shall be sufficiently comparable to that which the
candidate will use in the performance of their job. Production parts and NDT
equipment may be used for training.
3.6.2 Training and Examination Personnel
The Responsible Level 3 shall maintain overall control and cognizance over the NDT
training program, including designating and approving Examiners, instructors
and outside agencies.
3.6.2.1 Examiners
1. When necessary, Level 3 examiners shall be designated in writing by the
Responsible Level 3. All examiners shall be certified in accordance with BSEN4179.
As determined and documented by the Responsible Level 3, an Examiner can
prepare, administer and grade written or practical NDT examinations, and
administer all or part of the certification process in the method in which
certified.
2. The designated Level 3 Examiners are identified in Appendix A.
Page 3-12
3.6.2.2 Instructors
1. Instructors shall have the skills and knowledge to plan, organise, and
present classroom training and practical exercises in accordance with approved
course outlines. Instructors shall be designated or approved by the Responsible
Level 3.
2. The designated instructors are identified in Appendix A.
3.6.2.3 Outside Agencies
When an outside agency is used, the outside agency shall provide the AESC
with the names, evidence of qualifications and, if applicable, evidence of
certifications held by the personnel conducting the training and examinations.
3.6.3 Experience
1. Candidates for certification at Level 1, Level 2, or Level 3 shall have
sufficient practical experience to assure that they are capable of performing the
duties of the level for which certification is sought.
2. The minimum experience requirements for Levels 1 and 2 are provided in Table
2. The requirements for Level 3 are in Table 3 and 3.6.4.2, as applicable.
3. As documented in the written practice, on-the-job training for the purpose of
gaining experience shall be conducted by personnel certified in accordance with
EN4179.
3.6.3.1 Previous experience
A candidate’s documented experience with a previous employer may be
accepted by AESC only if such experience is documented and approved by the
Responsible Level 3.
3.6.3.2 Equivalent experience
For personnel certified under NAS 410, EN 4179 or other NDT qualification program,
the adequacy and equivalency of their previous experience to the requirements of
Tables 2 or 3 shall be determined and documented by the Responsible Level 3.
Page 3-13
Table 2 - Minimum Experience Requirements in Hours for Levels 1 and 2

Experience Tine in hours *
Method Level 1 Level 2 Level 2 without
(Trainee experience) with previous previous Level
Level 1 certification 1certification
PT 130 270 400
MT 130 400 530
ET 400 1200 1600
UT 400 1200 1600
RT 400 1200 1600
VT 70 140 210
TT 200 600 800
HT - 24 24
* Experience in multiple methods may be accumulated simultaneously. Experience in
method must be at least half this time when remaining time is spent working or
training in other NDT methods when approved by the responsible Level 3
Table 3 - Minimum Experience Requirements for Level 3 in penetrant and

magnetic particle, ultrasonic, eddy current and radiographic testing
College or University Level 2 or Equivalent

Experience
None 4 years
Two years of engineering or science study at a
2 years
technical school, college or university
Three to four years science or engineering
1 year
undergraduate degree
3.6.4 Emerging NDT Methods
The minimum required training and experience hours for methods used by AESC that
are not listed in paragraph 1.3, Table 1 and Table 2 shall be established by the
Responsible Level 3.
3.7 EXAMINATIONS
3.7.1 Purpose
1. Examinations to verify technical qualifications of candidates shall consist of a
general, specific and a practical examination for each method in which the
candidate is to be certified.
2. An examination for visual acuity shall also be conducted prior to the
candidate’s first certification and periodically thereafter.
3. The requirements for the vision examination, the questions or question
database used for the general and specific examinations and the checklist for
the practical examination shall be available for review by AESC customers.
4. Examination and test samples shall be made available to candidates only
during administration of the examinations.
Page 3-14
3.7.1.1 Vision Examination

1. The vision examination for Level 1, Level 2, and Level 3 personnel shall assure
that the applicant’s near vision and colour perception meet the requirements of
Table 4. Vision Requirements do not apply to instructors or auditors.
2. Near vision tests shall be administered annually and colour perception tests shall
be administered at least every five years. These tests shall be administered by
trained personnel designated by the Responsible Level 3 or by qualified medical
personnel.AESC shall ensure the flow-down of the Table 4 vision requirements
to all necessary personnel and/or facilities.
3. When vision correction is necessary to pass the visual acuity exam, vision
correction shall be worn during all testing/inspections.
4. Any limitations in colour perception shall be evaluated by the Responsible
Level 3 prior to certification and must be approved in writing.
Table 4 – Vision Requirements

Examination Requirements
Near vision 20/25 (Snellen) at 42 cm (16”) +/- 25.4 cm (1”) in at least one eye,
natural or corrected, or
Times Roman N4.5 point/Jaeger No. 1 at not less than 30 cm/12
inch in at least one eye, natural or corrected.
Colour Personnel shall be capable of adequately distinguishing and

perception differentiating colours using the Ishihara test and the number
of plates presented is to be documented.
3.7.1.2 General
1. The general examination for all levels shall be a closed book examination
consisting of questions that cover the cross-section of the applicable method at
the appropriate level.
2. A minimum of 1 0 questions shall be administered for the general
examination for Level-1 Limited.
3. A minimum of 40 questions shall be administered for the general
examination at Levels 1, 2 or 3. For the Level 3, the general examination
questions will address the general knowledge of other methods used by the
employer as well as the method for which certification is sought. Passing a “basic”
examination covering the other NDT methods used before passing any NDT
method examination shall be considered satisfactory evidence the other NDT
methods have been satisfactorily covered.
4. Possession of a current EN 473, i.e PCN/GEN or PCN/AERO, or ASNT NDT certificate
at the appropriate level by the candidate is satisfactory evidence that the general
examination requirement is satisfied as defined in Written Practice.
3.7.1.3 Specific
1. The specific examination for all levels shall be an open book examination
covering the requirements and use of the specifications, codes, equipment,
operating procedures, and test techniques the candidate may use in the
performance of his/her duties with AESC.
Page 3-15
2. A minimum of 30 questions shall be administered for the specific

examination at Levels 1, 2 and 3.
3. Reference materials such as specifications, tables, formulas, etc. may be
provided as determined by the Responsible Level 3 or Examiner. Questions
utilising such material shall require the understanding of the information
contained therein rather than merely finding its location.
3.7.1.3.1 Practical
1. The practical examination shall consist of a demonstration of proficiency in
performing tasks that are typical of those to be accomplished in the performance
of the candidate’s duties..If the candidate is required to demonstrate proficiency
in the application of the process as well as interpretation of results, hardware test
samples shall be used. The location and severity of flaws in the test sample
shall not be apparent to the candidate.
2. If the candidate is only required to interpret the results and not perform the
process of generating the image, the test samples may be images, such as
radiographs or other resultant test data.
3. A written checklist covering the topics detailed in the following sub-
paragraphs shall be developed by the Responsible Level 3 or Examiner to assure
adequate coverage and to assist in the administration and grading of the
examination. In addition to using the checklist, the Responsible Level 3 or
Examiner shall determine how the examination results obtained by the
candidate are to be documented (e.g. part maps, drawings, sketches, written
descriptions, etc.). All such documentation shall become part of the examination
and filed accordingly.
4. Possession of a current EN 473, i.e. PCN/GEN or PCN/AERO, or ASNT NDT
certificate at the appropriate level by the candidate is satisfactory evidence that
the practical examination requirement is satisfied as defined in Written Practice for
the Penetrant and Magnetic Particle methods and techniques.
3.7.1.3.2 Level 1
1. The candidate shall demonstrate proficiency by using a detailed written
instruction to process at least two test samples of differing configurations for each
method, with at least one test sample for each technique for which certification is
sought. When only one configuration of hardware is to be inspected on
certification, both test samples may be of the same configuration. The test
samples shall meet the definition in 3.3.31 and be representative of the specific
product to be encountered by the candidate in the performance of their duties
with AESC.
2. The candidate shall document the NDT results. The checklist shall include
proficiency in the use and standardisation of equipment and materials, adherence
to procedural details, and the documentation of results. If the Level 1 candidate is
to accept products, the checklist shall also include proficiency in the interpretation
and evaluation of indications
3.7.1.3.3 Level 2
3. The candidate shall demonstrate proficiency by using a written instruction to
process at least two test samples of differing configurations for each method, with
at least one test sample for each technique for which certification is
Page 3-16
sought. When only one configuration of hardware is to be inspected on

certification, both test samples may be of the same configuration. The test
samples shall meet the definition in 3.3.31 and be representative of the specific
product to be encountered by the candidate in the performance of their duties
with AESC.
4. The candidate shall document the NDT results in accordance with the
applicable acceptance criteria. The checklist shall include proficiency in the use
and standardisation of equipment and materials, adherence to procedural
details, the accuracy and completeness of interpretation and evaluations of
indications, and the ability to develop work instructions.
3.7.1.3.4 Level 3
1. The candidate shall demonstrate proficiency by preparing an NDT
procedure or work instruction appropriate to the current requirements of AESC
for the method. The procedure or work instruction shall be developed in
conjunction with the general and/or specific examination(s) required for
certification or recertification, as applicable. A procedure or work instruction
developed within the previous three months by the candidate may be used with
the approval of the Responsible Level 3.
2. When the candidate’s duties will include processing and/or acceptance/
rejection of products, proficiency in performing such tasks shall be demonstrated
by a hands-on practical examination equivalent to Level 2 in accordance with
3.7.1.3.2.
3. The results of the practical examination shall be documented and a checklist shall
be used to address the practical and technical adequacy of the procedures or
work instructions prepared by the candidate. When the candidate is to
accept/reject hardware, the adequacy of the interpretation and evaluation of
indications shall be documented.
4. The additional practical examination to accept/reject hardware is not
required for Level 3 who write or approve work instructions even if those
instructions are used by personnel to accept/reject hardware.
3.7.2 Administration of Examination
The administration and grading of all examinations shall be the responsibility of
the Responsible Level 3or Examiner. The Responsible Level 3 may delegate in
writing the administration and grading of all examinations using multiple choice or
true/false questions to non-Examiner personnel. All practical examinations shall
be administered by the Responsible Level 3 or Examiner. Responses to essay and
fill-in questions must be evaluated by the Responsible Level 3 or Examiner to verify
the certification candidate’s adequate understanding of the subject matter. In no
case can an examination be administered by AESC or by a subordinate.
3.7.2.1 Administration by an Outside Agency
When an outside agency is used to administer examinations, AESC shall
ensure that all individuals involved in the examinations meet the requirements of
this document. In all cases, the ultimate responsibility for compliance to this
procedure shall remain with AESC.
Page 3-17
3.7.2.2 Grading
1. The candidate for certification must achieve a minimum score of 70 % on each

individual examination. In addition, the candidate must detect all discontinuities,
flaws or conditions specified by the Level 3 during the practical examinations
and achieve a minimum score of 70%. The candidate must have an average score
of no less than 80% in order to be eligible for certification. All examination scores
shall be of equal weight in determining the average score. For example, if only
specific and practical examinations are administered for recertification, only those
scores shall be factored into the average score. If a general examination is also
given for recertification, the general score shall be factored into the average score.
2. For a Level 3 recertified under paragraph 3.8.6, the score for the practical
hands-on, if administered, will be used as the average score.
`
3. Scores for ASNT, EN473, ISO 9712 NDT certificates scored as “pass/fail”, and
used in lieu of the general examination per 3.7.1.2 shall be assigned a value of
80%.
3.7.3 Re-examination
Candidates failing any general, specific or practical examination shall receive
additional training before attempting re-examination of the failed exam. The
additional training shall be documented and shall address those areas found deficient
in the candidate’s skill or knowledge. The re-examination shall not use the same
written tests or test samples that were used in the initial examination. The re-
examination test must contain a minimum of 25% new questions.
3.8 CERTIFICATION
3.8.1 General
1. Personnel who have demonstrated that they possess the appropriate
qualifications are eligible for certification by AESC in accordance with this
document. Certification is not required for personnel who are trainees, NDT
auditors, or personnel performing specialised inspections using direct
readout instruments.
2. Certification shall be approved by the Responsible Level 3.
3.8.2 Records
AESC shall maintain personnel certification records as long as the certification is in
effect. The records maintained shall include, as a minimum:
1. Name of the certified individual;
2. Level, method, and technique(s) for which the individual is certified;
3. The latest written and practical examinations and the scores from
immediately previous exams;
4. Date and expiration of current certification(s);
Page 3-18
5. NDT training history, which identifies source, type of training, dates of

training, and course hours, and if applicable, the documentation required by
3.6.1.2 and 3.6.1.3;
6. NDT experience history, including any previous certifications, both with AESC
and previous employers sufficient to justify satisfaction of
experiencerequirements for qualification, and, if applicable, the
documentation required by 3.6.1.2 and 3.6.1.3;
7. Results of most recent (i.e. current) visual acuity and colour perception
examinations;
8. Extent and documentation of formal education when used to meet

qualification requirements;
9. The name and signature of the AESC representative authorising the
certification.
3.8.2.1 Record Availability

All training, qualification, and certification records shall be maintained in accordance
with this procedure and shall be made available for audit by AESC customers or
regulatory agencies. All such records, except for actual examinations, shall be made
available to the applicable employee upon request or upon leaving the company for
any reason. Examinations are to be made available for audit at the outside Agency
Examination Centre.
3.8.3 Loss of Certification
NDT Certification may expire, be suspended, or be revoked.
3.8.3.1 Expiration
Certifications for all levels shall expire when the certification interval has lapsed with
no re-certification issued. Certification for all levels is considered to expire at the end of
the corresponding month in which the certification began.
3.8.3.2 Suspension
Certification shall be suspended when employment is terminated, the visual
acuity examination is overdue, the individual does not perform in the method certified
for at least 12 consecutive months, or when the individual's performance is found to be
deficient in any manner
3.8.3.3 Revocation
Certification shall be revoked when the individual does not perform in the certified
method for at least 24 consecutive months or when the individual’s conduct is
found to be unethical or incompetent.
Page 3-19
3.8.4 Reinstatement of certification

Certifications that have been suspended may be reinstated when the cause for the
suspension has been corrected and the correction verified by the employer, or the
individual’s proficiency is verified by the responsible Level 3. Certifications that have
expired or been revoked may only be reinstated by specific and practical
examination equivalent to initial certification.
3.8.5 Recertification
Personnel are eligible for recertification as follows:
3.8.5.1 Level 1/2 Personnel
Level 1/2 personnel certified to this document shall be recertified at intervals not to
exceed five years. Recertification shall be accomplished by successful completion of
practical and specific examinations equivalent to those required for initial certification.
3.8.5.2 Recertification for Level 3 Personnel
Level 3 personnel certified to this document shall be recertified at intervals not to
exceed five years. Recertification shall be accomplished in accordance with paragraph
3.8.6 or by successful completion of specific and practical re- examination equivalent to
initial certification.
3.8.5.2.1 Hands-on Practical Examination

If equipment operation or accepting hardware is required as part of the Level 3’s
duties, an additional hands-on practical examination equivalent to Level 2 is required.
3.8.6 Credit System for Recertification of Level 3 NDT Personnel
This section specifies requirements for re-certification of the Level 3 NDT personnel
without examination. It applies only to those persons holding a valid Level 3 NDT
certification at the time of recertification.
3.8.6.1 Requirements:
Documentation for recertification shall be made to the Responsible Level 3 at least
14 days prior to the expiration date of the certification. Application for recertification
by the Responsible Level 3 shall be made to the employer. The candidate shall have
been employed in a Level 3 function for a minimum of 36 months (at least 12 of which
are in the last 24 months) within the previous five years in the method(s) for which
recertification is sought. The number of months is cumulative and does not need to be
consecutive months for validation purposes. Candidates shall provide objective
evidence that they have kept up to date with current NDT technology in the
method(s) for which they are seeking recertification by obtaining a minimum of 24
points during the five year period of certification, irrespective of the number of
certifications (methods) obtained, by engaging in one or more of the activities listed in
Table 5.
Page 3-20
3.8.6.2 Definitions
1. Committee or Panel Meetings: Meetings, conference, symposia, seminars, trade
association meetings, panels, etc. organized or sponsored by a regional, national
or international NDT organization or technical society. Foreign or international
meetings qualify if the sponsor(s) are national or international.
2. Committee Projects: Specific identifiable official activities of regional or
national technical societies, committees or work groups, such as round
robins or individual studies, preparation of guidelines, appendices,
specifications, recommended practices, procedures, codes or standards, etc.
Documentation may include memos or reports, drafts of committee output
documents, or official written comments submitted by the candidate on such
documents.
Page 3-21

Table 5 Level 3 Awarded Credited Activity (to BS EN 4179:2009)
Max
Point Points
Activity Criteria
Allocation per 5
years
Authorizing or co-authoring technical Sole Author 8

NDT papers, presentations or white Co-Author (contribution >30%) 4 16
papers Co-Author (contribution <30%) 2
Authoring, co-authoring or Custodian for

company or industry NDT specifications Each standard/specification 8 16
or standards
Attending technical sessions, seminars,
and committee or panel meetings
organized by: 1 day or 1 meeting 1
a. National or international technical NDT 2 days 2 16
societies, associations and institutes. 3 or more days 4
b. Inter-company NDT teams comprised
of members from several locations
NDT technical training instructor teaching

courses which are designed to prepare For each 8 hours of instruction 4 8
students for NDT qualification or other
academic qualifications
Participating in technical courses or For every 8 hours of documented

2 8
seminars instruction
Actual
Participating in technical courses or For actual Continuing Education
CEUs/ 16
seminars for which academic credit is Units (CEUs) or academic credit
credit
given earned
awarded
Non Destructive Testing examiner For each examination session 1 8
NDT related technical and/or scientific
publications published either internally For each published paper 4 8
or externally
Documented NDT contributions to
For each documented
company, technical society or industry 4 8
contribution
committee projects
Documented participation in NDT-related For each documented
4 8
studies, Appointments or investigations contribution
Documented continuous satisfactory

Written testament by employer 4 16
performance as a Level 3
Conduct external NDT audits For each external audit conducted 1 16
Attend equipment or trade show For each show attended 1 4
Page 3-22
APPENDIX A: List of Nominations and Responsible Persons or Organizations
Responsible Level 3
TRUONG THANH CHUNG
Outside Agency
Examiners
Instructors
Page 3-23
APPENDIX B-1
COURSE OUTLINE – PENETRANT INSPECTION LEVELS 1 AND 2
1. Forms of products
Day 1 (Hours 1 to 4) CHAPTER 1: Introduction to Penetrant Testing

THEORY Background history
Capabilities of penetrant inspection
Basic penetrant process
Leak detection
Reasons for selecting penetrant inspection
Personnel requirements
Equipment requirements
Advantages, capabilities, disadvantages and limitations of
pentrant inspection
Safety precautions
Types of penetrant
Methods of removal
Sensitivity
Developers
Classification of penetrant materials and processes
Systems or family concept
Basic penetrant processes
Equipment requirements
CHAPTER 2: Inspection and Interpretation

Lighting and facilities
Black light (UV-A) - sources, generation, hazards, fixtures and
intensity requirements
Ambient light restrictions
Visible and UV-A light intensity measurement
Black light intensity variables
Inspection conditions
APPENDIX B: Reference Literature: Standards and

Specifications
APPENDIX E: Glossary of Terms
Day 1 (Hours 5 to 8) Hour 5 to 8 Instructor Demo

PRACTICAL Fluorescent water-washable method
Fluorescent hydrophilic remover method
Dry powder developer - dust storm application
Non-aqueous developer – aerosol application Use
of PSM-5 panel – systems check
Pre-use checks – UV-A lights, refractometer, dry powder
contamination
Page 3-24
2. HOMEWORK Chapter 1 issued
Day 2 (Hours 9 to 12) Review of Homework Chapter 1

THEORY
CHAPTER 2: Inspection and Interpretation (continued)
Inspection, interpretation and evaluation
Classification of discontinuities
Manufacturing and service induced discontinuities
Evaluation of indications
Photography of indications
CHAPTER 3: Pre-testing, Cleaning, Pre-cleaning and

Post-cleaning
Pre-testing
Cleaning
Contaminants and soils Cleaning
processes Mechanical working
processes
Post-cleaning after penetrant inspection
CHAPTER 4: Mechanism, Properties and Application of

Penetrant
Requirements of a penetrant
Mechanism of a penetrant Penetrant
properties and sensitivity Application
of penetrant
Temperature limitations
Penetrant dwell
Day 2 (Hours 13 to 16) Hours 13 to 16 Student Practice
PRACTICAL Use of PSM-5 panel – systems check
Pre-use checks – UV-A lights, refractometer, dry powder
contamination
Practical Exercises
3. HOMEWORK Chapters 2, 3 & 4 issued
Day 3 (Hours 17 to 20) Review of Homework Chapters 2, 3 & 4

THEORY
CHAPTER 5: Penetrant Removal
Factors influencing removability Flaw
size and shape
Type of penetrant
Methods of removal
Water-washable penetrant removal
Lipophilic emulsifier and hydrophilic remover processes
Comparison of lipophilic and hydrophilic
Solvent removal
CHAPTER 6: Developers
Developer functions
Page 3-25
Mechanisms of developer action

Slovent action
Drying
Dry, water soluble, water suspendable and solvent-based
developers
Comparison of developers

PRACTICAL Practical Exercises
4. HOMEWORK Chapters 5 & 6 issued
Day 4 (Hours 25 to 29) Review of Homework Chapters 5 & 6

THEORY
CHAPTER 7: Materials and Process Control
New and in-use materials
Causes of material degradation
Frequency of materials verification and process control
checks
Materials control and process control testing
Penetrant Systems Monitor (PSM) procedure and storage
Systems performance testing
In-process penetrant testing
BS EN 3452:2000 Annex B process control tests
APPENDIX A: Writing of Reports and Instructions

PRACTICAL APPENDIX A: Writing of Reports and Instructions
Practical Exercises

THEORY
Review of Writing of Reports and Instructions
CHAPTER 8: Special Purpose Materials

Oxygen compatible penetrants
Low sulphur, low chlorine penetrants
High temperature penetrant materials
Dye precipitation penetrant system,reversed fluorescence
method,
thixotropic penetrant, plastic film developers and filtered
particle penetrants
APPENDIX C: Comparison of Methods
Course Review
Theory Review
Practical Review
Page 3-26
End of Course Examination
Debrief
Day 5 PRACTICAL Hours as available Student Practice

Practical Exercises
Training References - Penetrant

BS EN 1330-2 Non-destructive testing – Terminology – Part 2: Terms common to the
nondestructive testing methods.
BS EN 1330-1: Non-destructive testing-Terminology – Part 1 List of general terms.
BS M38: Guide to compilation of instructions and reports for the in-service Non-
Destructive Testing of Aerospace Products.
BS M39: Method for Penetrant Inspection of Aerospace Materials and Components.
BS EN 571-1: Penetrant Testing. Part 1: General principles for the examination.
BS EN 1289 Non-destructive examination of welds – Penetrant testing of welds.
Acceptance levels
BS EN ISO 3059: Non-destructive testing. Penetrant testing and Magnetic Particle testing.
Viewing conditions.
BS EN ISO 3452-2 Non-destructive testing. Penetrant testing. Testing of Penetrant
materials
BS EN ISO 3452-3 Non-destructive testing. Penetrant testing. Reference test block
BS EN ISO 3452-4 Non-destructive testing. Penetrant testing. Equipment
BS EN ISO 12706 Non-destructive testing – Terminology – Terms used in penetrant testing
QPL 25135: Qualified Products List.
MIL-I-25135: Inspection Materials, Penetrants.
ASTM E1417 Standard Practice for Liquid Penetrant examination.
Product Technology Classroom Training Handbook. BINDT.
Materials Processes for NDT Technology. ASNT.
Principles of Penetrants. C E Betz, Magnaflux Corporation.
Non-Destructive Testing Handbook, Vol 2, Liquid Penetrant Tests. ASNT.
ASNT Classroom Training Handbook originally published by General Dynamics.
ASNT Self Study Handbook originally published by General Dynamics.
Page 3-27
APPENDIX B-2
COURSE OUTLINE – MAGNETIC PARTICLE INSPECTION LEVELS 1 AND 2
Day 1 (Hours 1 to 4) Chapter 1: Introduction

THEORY Advantages of magnetic particle testing
Significant disadvantages of magnetic particle testing
Ferromagnetic and non-ferromagnetic materials
Magnetic ‘Domain’ Theory
Properties of the magnet, magnetic field and flux leakage
Chapter 2:Magnetizing Ferromagnetic Materials

Magnetic flow
Current flow
Direct and alternating current
Magnetic properties of materials
Formation of a Hysteresis loop
Appendix B: Reference Literature: Standards and
Specifications
Appendix E: Glossary of Terms
Day 1 (Hours 5 to 8) Hour 5 to 8 Instructor Demo

PRACTICAL Use of magnetic particle bench units – AC and Half Wave DC Use
of electromagnet – AC and DC modes
Pre-use checks – UV-A lights, ink concentration, current flow and
coil checks

THEORY
Chapter 3: Methods of Magnetisation
Circular magnetisation – current flow and threader bar
Longitudinal magnetisation – coil
Quick break technique
Magnetic flow
Induced current magnetisation
Combined electric current magnetisation
Chapter 4: Assessing Amperage

Single phase alternating current
Half wave and full wave rectification
MagAmps
Three phase full wave rectification
Current flow, threader bar, coil
Extenders
Magnetic flow
Prods
Meter readings and current flow for various waveforms
Relative depth of penetration
Methods for assessing current
Page 3-28
PART 3- WRITTEN PRACTICE– AESC/NDT/WP02

PRACTICAL Practical Exercises – assessing amperage and inspection

THEORY
Chapter 5: Detecting Media
Properties of magnetic particle materials
Dry powders Magnetic Inks
(wet) Preparation and use of
inks
Particle content and content checks
Standard test pieces
Comparison and advantages of wet and dry methods
Comparison of water and petroleum/oil suspension
Magnetic rubber inspection
Chapter 6: Equipment
Magnetisation using electrical current
DC surge
Coils and threader bars
Field and flux indicators (penetrameters)
Hall effect and tangential field strength meter (gauss meter)
Particle contents testing kit
Ketos ring
Lighting and facilities
Black light (UV-A) - sources, generation, hazards, fixtures and
intensity requirements
Ambient light restrictions
Visible light intensity measurement
UV-A light intensity measurement
Black light intensity variables
Inspection conditions
PRACTICAL Practical Exercises – assessing amperage and inspection Pre-use
checks – UV-A lights, ink concentration, current flow and coil
checks

THEORY
Chapter 7: Demagnetisation
Residual magnetisation
Demagnetisation process
Demagnetisation methods
Precautions
Chapter 8: Interpretation of Indications

Indications
Page 3-29
Interpretation
Viewing conditions
Defect and spurious indications
Changes in permeability and magnetic writing
Confirmation of indications
Appendix A: Writing of Reports and Instructions

PRACTICAL APPENDIX A: Writing of Reports and Instructions
Practical Exercises
Day 5 (Hours 33 to 40) Review of Homework No. 4

THEORY
Review of Writing of Reports and Instructions
Chapter 9: Practical Procedures

Inspection methods – continuous and residual
Types of particles
Surface preparation, degreasing and cleaning
Initial demagnetisation
Instruction application
Residual magnetisation
Inking and magnetisation
Viewing and marking indications
Assessment and recording flaws
Demagnetisation
Cleaning and surface protection
Appendix C: Comparison of Methods
Course Review
Theory Review
Practical Review
Debrief
Day 5 PRACTICAL Hours as available Student Practice
Practical Exercises
Training References – Magnetic Particle

nondestructive testing methods
BS EN 1330-1: Non-destructive testing-Terminology – Part 1 List of general terms
M38: Guide to compilation of instructions and reports for the in-service Non-Destructive
Testing of Aerospace products.
Page 3-30
BS EN ISO 3059: Non-destructive testing. Penetrant testing and magnetic particle

testing. Viewing conditions
BS 1330-7: Terminology NDT - Magnetic Particle Flaw Detection.
BS EN ISO 9934-1 Non-destructive testing, Magnetic particle testing. General principles
BS EN ISO 9934-2 Non-destructive testing, Magnetic particle testing. Detection media
BS EN ISO 9934-3 Non-destructive testing, Magnetic particle testing. Equipment
ASTM E1444 Standard practice for Magnetic Particle Examination.
Product Technology Classroom Training Handbook. BINDT
Materials Processes for NDT Technology. ASNT.
Principles of Magnetic Particle Testing, C E Betz, Magnaflux Corp., Chicago. 1967.
Non-Destructive Testing handbook, Vol 6 - Magnetic Particle Testing. ASNT.
ASNT Classroom Training Handbook originally published by General Dynamics.
ASNT Self Study Handbook originally published by General Dynamics.
Page 3-31
ANNEX B-3
COURSE OUTLINE – EDDY CURRENT INSPECTION LEVELS 1 AND 2
Day 1 (Hours 1 to 4) CHAPTER 1: Basic Principles of Eddy Currents

THEORY Applications
Advantages
Limitations
Eddy currents
Alternating current in a coil
Magnetic coupling
Production of eddy currents
Lenz’s Law
Eddy current inspection
Calibration of high frequency meter instruments Inspection
using high frequency meter instruments Calibration of high
frequency phase display instruments Inspection using high
frequency phase display instruments
CHAPTER 2: Factors affecting Eddy Currents

Conductivity
Permeability
Ferrous, non-ferrous, paramagnetic and diamagnetic
materials
Frequency
Geometry
Proximity
Discontinuities
Probe handling
Depth of penetration

Specifications

Day 1 (Hours 5 to 8) Hour 5 Instructor Demo Hours 6 to 8 Student
PRACTICAL Impedance Bridge Practice Impedance
Instrument Bridge Instrument
Conductivity Meter Conductivity Meter
Practical Exercises

THEORY
CHAPTER 3: Electrical Theory
Direct current (DC) Direct current
theory Alternating current (AC)
theory
Page 3-32

PRACTICAL Impedance Bridge Instrument
Conductivity Meter
Practical Exercises

THEORY
CHAPTER 4: Phase Analysis
Current/Voltage phase relationship
Conductivity changes
Dimensional changes
Change in frequency
Change in permeability
Changes in probes
Choice of operating point and f/fg
Characteristic frequency
PRACTICAL Impedance Plane Instrument Practice
High Frequency Application Impedance Plane Instrument
High Frequency Application
Practical Exercises

THEORY
Review of Chapter 4: Phase Analysis
CHAPTER 5: Practical Impedance Plane Analysis

Reviewing impedance plane fundamentals Presentation
of conductivity
Lift-Off (coating thickness measurement)
Selection of frequency
Corrosion and cracks in subsurface layers
Location of 2nd layer corrosion or cracking
Change of probe
Change of permeability

Conductivity Measurement Impedance Plane Instrument
High Frequency Application
Conductivity Measurement
Practical Exercises
Page 3-33
4. HOMEWORK Chapters 5 issued

THEORY
CHAPTER 6: Coils and Probes
Surface coils
High frequency surface probes
Low frequency surface probes
Encircling coils
Internal coils
Fill factor
Coil magnetic fields
Ferrite core probes Air
core probes Shielded
coil probes Saturation
probes
Factors effecting eddy current probe performance
CHAPTER 7: Coil Arrangement

Single absolute coil
Double absolute coil
Single differential coil
Double differential coil Self
comparative system
External comparative system
Differential Coils Impedance Plane Instrument
High Frequency Application High Frequency Application
Differential Coils
Practical Exercises

THEORY
Review of Days 1 to 5
CHAPTER 8: Practical Eddy Currents

High frequency crack detectors (surface faults)
Hole inspection
Low frequency tests sets (variable frequency)
Corrosion detection-subsurface
Crack detection-subsurface
Page 3-34
Day 6 (Hours 45 to 48) Hour 45 to 46 Instructor Hours 47 to 48 Student

PRACTICAL Demo Practice
Impedance Plane Instrument Impedance Plane Instrument
Low Frequency Application Low Frequency Application
Corrosion Detection- Corrosion Detection-
subsurface subsurface
Crack Detection-subsurface Crack Detection-subsurface
Practical Exercises

THEORY

PRACTICAL Writing of a report and an instruction
Practical Exercises
Day 8 (Hours 57 to 60) Review of Reports and Instructions
THEORY
CHAPTER 9: Use of Filters
Modulation
Eddy current instrument filter usage
Filters
Selection of frequency
CHAPTER 10: Bolt And Fastener Hole Inspection using

Rotating ‘Spinning’ Probe Equipment
Advantages
Probes
Displays – time-base and spot
Interpretation
Effect of frequency
Calibration blocks
Calibration
Inspection
Spinning probes
Impedance Plane Instrument Impedance Plane Instrument
Use of Filters Use of Filters
Bolt And Fastener Hole Bolt And Fastener Hole
Inspection Inspection
Practical Exercises

THEORY
CHAPTER 11: Dual Frequency Inspection
Page 3-35
Overview of dual frequency inspection

Reference standard
Principle of dual frequency calibration
Choice of Frequency 1 and Frequency 2
Practical calibration
CHAPTER 12: Basic Test Set Design

Bridge circuits
Bridge circuits with resonant probes
Pure impedance measuring circuits
Phase comparison circuits
Warning devices
Impedance plane analysis display instruments
Cathode Ray Tube

Dual Frequency Calibration Impedance Plane Instrument
Dual Frequency Inspection Dual Frequency Calibration
Dual Frequency Inspection
Practical Exercises

THEORY
Course Review
Theory Review
Practical Review
Debrief
PRACTICAL Impedance Plane Instrument
Completion of Exercises as required
Practical Exercises
Training References – Eddy Current

BS EN 1330-1: Non-destructive testing-Terminology – Part 1 List of general terms
nondestructive testing method
BS EN 1330-5: Non-Destructive Testing – Terms used in eddy current testing.
Page 3-36
Product Technology Classroom Training Handbook. BINDT

Materials and Processes for NDT Technology. ASNT.
Eddy Current Testing, Classroom Training Handbook (CT-6-5): ASNT.
Eddy Current Testing, Programmed Instruction Handbook (PI-4-5): ASNT.
Non-Destructive Testing Handbook, Volume 4 - Electromagnetic Testing. ASNT.
ASNT Self Study Handbook (originally published by General Dynamics).
ASNT Classroom Training Handbook (originally published by General Dynamics).
Page 3-37
ANNEX B-4
COURSE OUTLINE – ULTRASONIC INSPECTION LEVELS 1 AND 2
Day 1 (Hours 1 to 4) CHAPTER 1: Generation and Detection of Ultrasonic

THEORY Energy
The nature of sound
Acoustics
Transmission of sound
Basic application to the detection of defects
Electro-acoustic transducers
Natural piezo-electric crystals
Synthetically grown crystals
Artificially produced piezo-electric materials
Polarized PVDF film
Curie temperature
Piezo-electric transducer qualities
Standing waves
Resonant frequency

Specifications

PRACTICAL Equipment calibration Practice
Practical Exercises

THEORY
CHAPTER 2: Propagation of Ultrasonic Waves in
Materials
Modes of propagation:
Compressional, Shear, Surface, Plate (Lamb), Creeping
CHAPTER 3: Sound Distribution from a Crystal

Huygens Principle
Near field
Far field
Beam Axis
Sound attenuation in the far field Calculation
of near field and beam spread Calculation of
beam diameter
Beam profile
PRACTICAL Characteristics of Reflectors Practice
Practical Exercises
Page 3-38

THEORY
CHAPTER 4: Behaviour of Ultrasound at Material
Interfaces (Reflection)
Reflection
Characteristic acoustic impedance Significance of
acoustic impedance variations Couplant
Reflection and refraction of ultrasonic energy
Reflection of incident compressional wave
Reflection of incident shear wave
Main applications in ultrasonic inspection
Effect of beam spread
Plate or wall thickness
Applications
Relative amplitudes and angles

PRACTICAL Acoustic Impedance Practice
Beam spread Practical Exercises

THEORY
CHAPTER 5: Behaviour of Ultrasound at Material
Interfaces (Refraction)
Refraction of incident compressional wave
First critical angle
Second critical angle
Refraction of incident shear wave
Main applications in ultrasonic inspection
Effect of temperature changes
Skip distance
Path length
PRACTICAL Shear wave calibration Skip Practice
distance Practical Exercises
Path length
Page 3-39

THEORY
CHAPTER 6: Probe Design, Operating Frequency and
Identification
Probe design
Probe design considerations
Piezo-electric elements
Probe operating frequency
Natural resonant frequency
Pulse length and backing members
Q and bandwidth
Sensitivity, acoustic impedance and resolving power
Optimum sensitivity and resolution
Probe performance
Probe identification
Probe types: compressional, shear, surface, lamb, delay, twin,
water immersion and water irrigated, roller, focussed,
paintbrush (mosaic)
CHAPTER 7: Flaw Detector Principles

Basic components of flaw detector, including:
Cathode ray tube, pulse generator, prf, pulse transmitter,
timebase sweep generator, amplifier, reject, gain,
attenuators, signal processing, filters, gates, displays, A-scan
presentation.
PRACTICAL Flaw detector: Practice
PRF, filters, displays, damping, Practical Exercises
pulse length, reject.
Page 3-40
Day 6 (Hours 41 to 44) Review of Homework Chapter 6 & 7

THEORY
CHAPTER 8: Practical Applications

Advantages, limitations and disadvantages of ultrasonics
Factors affecting the sensitivity and resolution of an
ultrasonic technique
including: probe, test set, specimen, flaw
Probe selection
Day 6 (Hours 45 to 48) Hours 45 to 48 Student Practice Writing

PRACTICAL of a Report and an Instruction Practical
Exercises
6. HOMEWORK Chapters 8 issued

THEORY
Review of Reports and Instructions
CHAPTER 9: Calibration and Performance Checking of
Equipment
Calibration blocks
Timebase calibration and linearity
Amplifier linearity and calibration of gain control
Probe frequency, pulse shape and duration
Sensitivity and signal-to-noise ratio
Dead zone
Beam width
Resolution
Probe index, beam angle, squint
Periodicity and acceptance criteria
Calibration and Performance Calibration and Performance
Checking of Equipment Checking of Equipment
Practical Exercises
Page 3-41

THEORY
CHAPTER 10: Immersion Techniques
Immersion systems
Advantages and disadvantages of immersion testing
Water gap
Probes
Scrubbers
Back reflector method
Effect of curvature on sound beam
CHAPTER 11: Defect Sizing

The Decibel
Equivalent flat bottom hole (FBH) method
FBH reference blocks
Distance, gain, size (DGS) method
6 dB drop method
20 dB drop method
Maximum amplitude method
Distance amplitude correction (DAC) curves
Reject
PRACTICAL Demo Practice Immersion
Immersion system system Defect sizing
Defect sizing Practical Exercises
Day 9 (Hours 65 to 68) THEORY Review of Homework Chapters 10 & 11
CHAPTER 12: Other Ultrasonic Methods

B-Scan
C-Scan
Resonance method
Digital readout thickness gauges
Acoustic emission

PRACTICAL Immersion system
Defect sizing
Practical Exercises
Page 3-42
Day 10 (Hours 73 to 80) Review of Homework Chapters 12

THEORY
Course Review
Theory Review
Practical Review
Debrief
PRACTICAL Completion of Exercises as required
Practical Exercises
Training References - Ultrasonic

BS M36: Method for ultrasonic testing of special forgings by an immersion technique using
flat-bottomed holes as a reference standard.
BS EN 1330-4: Non-Destructive Testing – Glossary of terms used in non-destructive testing.
Ultrasonic flaw detection.
BS EN 12668-3 Non-Destructive Testing – Characterization and verification of
equipment: Part 3 Combined equipment.
BS EN 583-1 Non-destructive testing –Ultrasonic examination – Part 1: General
principles
BS EN 583-3 Non-destructive testing –Ultrasonic examination – Part 3: Transmission
technique.
BS EN 583-5 Non-destructive testing –Ultrasonic examination – Part 5: Characterization and
sizing of discontinuities
BS EN 12223 Calibration block No.1 for ultrasonic examination
BS EN 27963 Calibration block No.2 for ultrasonic examination of welds
MIL-STD-2154: Process for inspection ultrasonic weld metals
MIL-STD-2175: Castings - classification and inspection of.
Product Technology Classroom Training Handbook, BINDT
Materials and Processes for NDT Technology. ASNT.
Non-Destructive Testing Handbook, Vol 7, Ultrasonic Testing, ASNT
ASNT Self Study Handbook (originally published by General Dynamics)
ASNT Classroom Training Handbook (originally published by General Dynamics
Page 3-43
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS
PART 4
NDT SPECIFIC PROCEDURES
& WRITTEN INSTRUCTIONS
Page 4-1
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/PR/ET02
4.1 EDDY CURRENT INSPECTION PROCEDURE

4.1.1 Scope
This procedure establishes the AESC minimum requirements for all eddy current
inspections carried out on aircraft structures, components and engines under the
jurisdiction of any aviation authority and may be used as a contractual requirement for
a subcontractor.
4.1.2 Referenced Documents
1. The following documents form a part of this practice to the extent specified
herein.
a. NAS 410 to latest revision - Certification and Qualification of
Nondestructive Test Personnel.
b. EN 4179 to latest revision - Qualification and Approval of Personnel for
Nondestructive Testing.
c. AESC Written Practice No: AESC/NDT/MANUAL/002 - Training, Qualification
and Certification Nondestructive Test Personnel.
d. Boeing NDT Manuals
e. STANDARD PRACTICES MANUAL 32-09-01 (MESSIER-BUGATTI)
f. GOODRICH NDT Manual 32-40-74
2. Order of Precedence – In the event of conflict between the text of this
procedure and AESC references cited herein, the text of this procedure takes
precedence. In the event of conflict between the text of this procedure and OEM
or Aviation Authority references cited herein and aircraft maintenance practices,
the text of OEM, Aviation Authority or aircraft maintenance procedures takes
precedence
4.1.3 Terminology
4.1.3.1 Definitions:
1. NDT Method: a type of NDT e.g. ultrasonic, magnetic particle.
2. NDT Procedure: a company document detailing control of NDT.
3. NDT Technique: A subdivision of an NDT method e.g. yoke technique.
4. NDT Code or Specification: a public document controlling standards of
NDT application e.g. EN4179, Aircraft NDT Manuals, ASTM Standards.
5. NDT Instruction: A detailed step-by-step work sheet for application of a
particular technique to a particular product or component. May be
substituted by a Service Bulletin (SB) or Airworthiness Directive (AD).
6. Null/Balance: to zero the equipment.
7. Scan: to move the probe over the surface of the specimen.
Page 4-2
8. Indication: any disturbance of the eddy currents causing a change in the

screen or meter response.
9. HFET: High frequency eddy current testing.
10. LFET: Low frequency eddy current testing.
11. Impedance Plane Display: a two dimensional display on a screen showing
amplitude and phase changes of a signal from the eddy currents.
4.1.4 Safety
There are no special safety precautions related to this method. However inspectors
should be aware of standard safety practices within AESC including operations in and
around aircraft, within the hangar and on the apron.
4.1.5 Personnel
This procedure is to be performed by qualified and certified NDT inspectors. NDT
inspectors shall meet the requirements detailed within AESC Written Practice as Level
1, 2 or 3 inspectors. Level 1 personnel shall only work with written instructions under
Level 2 supervision and shall not release to service any components.
4.1.6 Identification and Datum Points
No parts, materials, or aircraft shall be inspected unless there is clear
identification such that the part, material or aircraft is traceable. Wherever indications
are recorded there shall be a datum referenced in any records such that the location of
the indication can be clearly identified later.
4.1.7 Surface Preparation
No eddy current inspection shall be undertaken unless the scan surface has been
inspected and found to be smooth and clean, free of debris and dirt.
4.1.8 Extent of Inspection
No eddy current inspection shall be carried out unless the scan area and anticipated
defect depth and location is clearly identified.
4.1.9 Equipment Specification
No eddy current inspection shall be carried out unless the equipment required to
complete the test is detailed at a level generically such that suitable equipments are
confidently and easily identified.
4.1.10 Equipment Calibration
All calibration shall be controlled by clear unambiguous instructions that define an
objective and repeatable sensitivity standard that clearly defines defect
indications from other factors that may effect the eddy current inspection.
4.1.11 Equipment Annual Performance Checks (annual calibration)
Equipment shall be performance checked on an annual basis and shall be
marked with a label identifying the due date for next performance check.( next due
calibration date )
Page 4-3
4.1.12 Equipment Checks

No eddy current equipment may be used for inspection purposes unless it is first
checked for serviceability, battery condition and correct functioning of all probes, coils
and controls. In the event that an equipment is found to be unserviceable, it shall be
clearly marked as such and removed from service until it is repaired.
4.1.13 Instruction Details
1. Instructions for Eddy Current Inspections shall take the form of:
a. Manufacturer nondestructive test manual b.
Airworthiness Directives
c. Service Bulletins
d. AESC Instructions (generic or specific)
2. A Level 1 certified inspector shall not carry out an inspection without
reference to an instruction as defined above. All AESC instructions shall be
approved by Level 3. Level 1 inspectors shall be trained by a Level 2/3 on
instruction compliance, as necessary to ensure competence prior to exercising
independent inspections.
3. AESC NDT Instructions shall be written to be understood by a Level 1
inspector and shall include the elements listed below as a minimum.
4. Foreword, status and authorization:
a. A unique reference number b.
Purpose of the test
c. Originator’s name, signature and date
d. Authorizing person’s name, signature and date
5. Personnel:
The minimum level of certification required to apply the instruction
6. Apparatus to be used:
Equipment to be used together with settings
7. Product/area to be tested:
Component identification, brief description and a drawing if appropriate
8. Test conditions:
a. Pre-test preparation of the test area b.
Post test cleaning and of test object
Page 4-4
9. Detailed instructions for application of test:

a. Step-by-step instructions in the application of the NDT technique with
reference to sketches if appropriate including pre-calibration and post
calibration checks.
b. A statement instructing the inspector on actions to be taken in the event that
the instruction cannot be applied.
10. Recording and classifying results:
Action to be taken when defect are detected.
11. Reporting the results
4.1.14 Assessment of Test Results

The instruction must specify the minimum size and type of indication sought and
where applicable, the method of classification and sizing to be employed.
4.1.15 Reporting of Test Results
Reports of inspection results shall be in accordance with AESC MOE. Where requested
by QA, normally on location of a rejected flaw, the Head of NDT may be asked to
generate a detailed report. Such a report shall contain the following information
headings as a minimum and each shall have a detailed narrative with accompanying
digital images and drawings as required.
1. Ad, SB, Procedure/Instruction Reference
2. Component part number, serial number, aircraft registration
3. Equipment used with serial number.
4. Equipment settings
5. Defect location, size and description
6. Status of indications, “Rejected”, “Acceptable”, “in limits” etc.
7. Inspector’s name and qualification
8. Inspector’s signature, Head of NDT’s signature
4.1.16 Non-Compliance Statement
Any inspection that cannot be complete for technical reasons beyond the control of
the inspector shall be reported to the Head of NDT for investigation.
4.1.17 Attachments
None
Page 4-5
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/PR/MT02
4.2 MAGNETIC PARTICLE INSPECTION PROCEDURE

4.2.1 Scope
1. This procedure establishes the AESC minimum requirements for conducting
magnetic particle inspection of ferromagnetic materials.
2. The magnetic particle examination processes described in this procedure are
applicable to in-process, final, and maintenance (in-service) inspections.
1. The following documents form a part of this practice to the extent specified
herein.
a. NAS 410 to latest revision - Certification and Qualification of Nondestructive
Test Personnel.
Non-destructive Testing.
c. AESC Written Practice no. AESC/NDT/MANUAL/002 - Qualification and
Certification of personnel for NDT.
d. ASTM Standards
e. ASTM E1444
f. Standard Practice Manual 32-09-01 section 42 (Messier Bugatti).

g. GOODRICH NDT Manual 32-40-75.
or Aviation Authority references cited herein and aircraft maintenance practices, the
text of OEM, Aviation Authority or aircraft maintenance procedures takes
precedence.
4.2.3 Terminology
4. NDT Code or Specification: a public document controlling standards of NDT
application e.g. EN4179, ASTM Standards.
particular technique to a particular product or component. May be substituted by a
Service Bulletin (SB) or Airworthiness Directive (AD).
6. Component: the part(s) or element(s) of a system described, assembled, or
processed to the extent specified by the drawing.
Page 4-6
7. In-service: refers to components that are in use or storage for their intended
function
8. Linear indication: magnetic particle indications with at least a three to one
length to width ratio.
9. Reprocess: repeat, after cleaning, the application and appropriate processing of
magnetic particle inspection (as required).
4.2.4 Significance and Use

1. This procedure establishes the A E S C basic parameters for controlling the
application of the magnetic particle method.
2. Safety. There are no special safety precautions related to this method. However
inspectors should be aware of standard electrical safety practices within AESC
including operations in and around the facility and the risk of burning and fire for this
method.
4.2.5 Classification
Magnetic particle techniques covered by this procedure shall be of the following

types.
1. Head shots
2. Coil shots
3. Yoke techniques
4. Permanent magnetic techniques
5. Wet continuous
6. Wet residual
4.2.6 General Practices
1. Responsibility for NDT Examinations - Unless otherwise specified by the Original
Equipment Manufacturer (OEM) or recognised aviation authority, AESC is
responsible for the performance of all NDT examination requirements as
specified herein.
2. Specifying – When NDT examination is required in accordance with this
procedure, instructions, ADs and SBs shall specify the criteria by which the
acceptability of components is to be evaluated. In any other cases appropriate NDT
instructions shall be used and shall define or specify objective reject criteria.
3. Personnel Qualification – Personnel performing NDT examinations to this
practice shall be qualified and certified in accordance with the AESC Written Practice
No: AESC/NDT/MANUAL/002 which complies with the requirements of NAS
410/EN4179.
4. Agency Qualification - N/A
5. Qualified Materials – Only materials from customer-approved suppliers may be used.
Page 4-7
6. Equipment and Facilities – Processing equipment used in the magnetic particle

examination process shall be constructed and arranged to permit a uniform and
controlled operation. The equipment shall meet all applicable national and local
safety requirements as well as the requirements specified herein.
7. Viewing Areas – Areas where parts are reviewed shall be kept clear at all times.
For fluorescent particle examination, the ambient visible light background shall not
exceed 5 lux at the examination surface. The black lights shall provide a minimum of
1500µW/cm² at the examination surface. Black lights shall meet the requirements of
7.5.1. Viewing areas for portable magnetic particle examination shall utilize dark
canvas, photographer’s black cloth, or other methods to reduce the visible light
background below 5 lux during examination and black light intensity shall meet the
above requirements.
4.2.7 Process Controls
4.2.7.1 Where magnetic particle is applied using a total loss system the process control
checks applicable to that suspension are not required. This exemption does not cancel
any other checks that are required for process control.
4.2.7.2 Located Hanoi
4.2.7.2.1 Equipments
1. Magnetic test bench
2. AC magnetic Yoke
3. Black light lamp
4. Field indicator
5. Gauss/Teslameter
6. UV Light meter
7. White light meter
4.2.7.2.2 Accessories
1. QQI
2. KETOS Steel Ring
3. Central Conductor
4. Magnetic Pie
4.2.7.2.3 Ferromagnetic Suspensions :

Prepared Bath 14AM
Page 4-8
4.2.7.3 Located HCM

4.2.7.3.1 Equipments
1. Gauss/Teslameter
2. Field indicator
3. Magnetic Yoke -DC

4. Ultraviolet Lamp
4.2.7.3.2 Accessories
4.2.7.3.3 Ferromagnetic Suspensions
1. Prepared Bath 14AM

4.2.7.4 Preparation of the testing agent / suspension
4.2.7.4.1 Turn on the machine pump. Pour the concentrate directly into the bath tank of the
machine.
4.2.7.4.2 Run agitator pump for several minutes
Page 4-9
Table 1: Periodic Inspection of Installation
Frequency Conditions to be
Nature of the Inspection 6 fulfilled and methods:
Shift Day Week Month months
Testing agent/suspension
- Brilliance of fluorescent x As per 4.2.7.5.1
- Discoloration x As per 4.2.7.5.2
- Concentration x As per 4.2.7.5.3
- Contamination x As per 4.2.7.5.4
- Tank Level x Visual: minimum tank level
x As per 4.2.7.5.5
- Viscosity
Machine x
- UV light intensity x As per 4.2.7.6.1
- White light intensity x As per 4.2.7.6.2
- Internal short circuit check x As per 4.2.7.7.3
- Max and min coil current output x As per 4.2.7.7.1
- Head shot current output As per 4.2.7.7.2
Measuring Device x
- Ammeter x As per 4.2.7.7.4
- UV light meter x To meet accuracy ±5%
- White light meter x To meet accuracy ±5%
- Gauss Meter
System performance check X
- Current Flow X As per 4.2.7.8.1
- Coil Magnetization As per 4.2.7.8.2
4.2.7.5 Examining the testing agent / suspension

4.2.7.5.1 Brilliance of fluorescent
1. Make a comparison between a standard sample of 'used' testing agent and
'unused' testing agent under black (UV) light for brilliance of particle
fluorescence.
2. Record the result .
4.2.7.5.2 Discoloration
1. Check the contamination of the suspension for clarity and absence of yellow
fluorescence under black light. Check for lint, dirt or scale.
4.2.7.5.3 Concentration
1. Run the pump for at least 30 minutes and at the same time thoroughly agitate and
mix by hand all suspension which has settled upon the screen and along the
bottom of the tank.
2. Fill centrifuge tube to the 100ml mark with suspension directly from the hose.
Demagnetize the suspension and allow the suspension to stand for 60 minutes for oil
based or 30 minutes for water based to settle.
Page 4-10
3. Read the volume of the settled suspension in the tube. Settlement flask shall lie
within the following:
Fluorescent ink – 0.1 to 0.3ml. Preferred 0.1 to 0.15
4. If the suspension is low in particle content, brush tank bottom to lift particles or add
magnetic particle to obtain the required concentration.
5. If the suspension is high in particle content, add fluid to obtain the required
concentration.
6. Record the result.
4.2.7.5.4 Contamination
From paragraph 4.2.7.5.3, check for the following:
1. Examine the liquid above the precipitate and compare with fresh suspension
under black light. The liquid shall not show a noticeable difference and shall not
fluoresce.
2. Examine the precipitate. If two distinct layers can be seen, read the volume of each
layer. The top layer volume (contamination) shall not exceed 10% of the bottom
layer volume and the contamination layer shall not fluoresce.
4.2.7.5.5 Viscosity (Subcontracted)
The viscosity of suspension shall be checked on 6 monthly basis and shall be
maintained below 5.0 centistokes at room temperature.
Note: this check is necessary only if the solution remains in the tank more than 6
months.
4.2.7.5.6 All the results for paragraphs 4.2.7.5.1 – 4.2.7.5.4 shall be recorded .
4.2.7.5.7 If any unsatisfactory results are obtained for the test layout in paragraphs 4.2.7.5.1,
4.2.7.5.2, 4.2.7.5.4 or 4.2.7.5.5, then the agent/suspension shall be replaced.
4.2.7.6 Inspection Station

4.2.7.6.1 UV Light Intensity
1. Expose the sensor cell of the UV intensity meter to the black light.
2. Read off the scale.
3. The scale shall be not less than 1500µW/cm2 at the part being examined where the
distance between the UV light filter and UV light intensity meter shall be not less than
381mm (15 inches). The wavelength of the black light shall be in the range of 3200
to 4000 Angstrom.
4. Record the results.
4.2.7.6.2 White light Intensity
1. Expose the sensor cell of the light intensity meter to the visible light at the
inspection area with all adjacent black lights turned “on” and directly under the black
light used for inspection.
Page 4-11
2. Read off the scale.

3. The white light intensity shall not exceed 5 lux measured at the inspection
surface with black light at 15 inches from the inspection surface.
4. Record the results
4.2.7.6.3 Visible Light Intensity
1. Visible light shall be used when examining with non fluorescent magnetic
particles and for interpretation of indications found with fluorescent magnetic
particles. a minimum light intensity of 100fc (1000 lux) shall be available at the
surface of the part undergoing examination or evaluation
4.2.7.7 MPI Machine
4.2.7.7.1 Maximum and minimum coil current output.
1. Set the controls for the machine to the maximum and minimum current value.
Pulse the current for both values.
4.2.7.7.2 Head shot current output (Electrical Capacity)
1. At minimum and maximum shall be determined, with a one (1) inch diameter
copper bar, 18 inches long between the head or electrodes. Ensure contact at ends is
good.
4.2.7.7.3 Internal short circuit check
1. Set for maximum amperage output. Set for “Head Shot”. Any deflection of the
ammeter when the current is activated with no conductor between the contacts is an
indication of an internal short circuit.
4.2.7.7.4 Ammeter Accuracy
1. The equipment meter reading should be compared to those of a calibrated
control test meter incorporating a shunt or current transformer connected to
monitor the output current.
2. The equipment meter reading shall not deviate by more than ±10% of full scale
relative to the actual current values as shown by the test meter in two positions of
the meter in each range setting.
4.2.7.8 System Performance Check.
4.2.7.8.1 Current Flow – Ketos Ring with permanently attached QQI.
1. Use a 1" to 1 3/16" diameter copper bar with 16" to 24" length for the Ketos
Ring check.
2. Place the conductor through the center of the Ketos ring.
3. Center the Ketos ring on the length of the conductor.
Page 4-12
4. Magnetize the Ketos ring circularly by passing the current specified in Annex I
through the conductor.
5. Apply the suspension to the Ketos ring using the continuous method.
6. Examine the Ketos ring within 1 min after current application under a black light of not
less than 1000 μW/cm2
7. The number of the holes indications shall meet or exceed those specified in table
2 and the indications on the QQI shall be clearly visible
9. Any observed deviation of sensitivity day to day shall be investigated
Table 2: HANOI NDT Shop Amperage and hole indication for KETOS RING
mag benches.
Model No:]
Amperage Minimum number of
Type of suspension
(FWDC OR HWDC) holes indicated
Fluorescent oxide(wet) 1400 [TBD]
2500 [TBD]
3400 [TBD]
4.2.7.8.2 Coil Magnetization (Test piece as per figure 13 of BS 6072).

1. Place the coil test piece at the bottom of the test coil.
2. Energize the machine with 300A (AC) or 430 A (DC).
3. Observe the strong transverse hole indications shows at the middle of the test
piece.
4. The indication shows that the coil magnetization is good condition.
4.2.7.9 MP I Machine Operation
1. Local instructions for MT machines at HAN [TBD].
a. User’s care and instructions for Magwerks.

4.2.7.10 Magnetization (As per ASTM E 1444)
The current shall produce a peak tangential-field strength in the range of 30 to
60 gauss (2.4 to 4.8 kAm-1) or in the range of 80 to 160 gauss according to
manufacture requirement in all areas to be inspected.
Gauss meter readings shall take precedence over calculated current
requirements.
4.2.7.10.1 Circular magnetization
Page 4-13
1. Direct Circular Magnetization. The current shall be from 300 to 800 A/in of part
diameter (12 to 32 A/mm)
2. Central Conductor Circular Magnetization.
a. Centrally Located Conductor. The current as per para 7.10.1 (1) shall be
applied.
b. Offset Central Conductor. The current as per para 7.10.1(2) shall be applied
except that the diameter shall be considered the sum of diameter of the central
conductor and twice the wall thickness.
4.2.7.10.2 Longitudinal magnetization
Longitudinal magnetization shall be used for those parts that are at least two times as
long as they are wide (i.e. L/D ≥ 2)
The peak current for longitudinal inspection shall be calculated as follows: For
parts positioned at the bottom of the coil:
NI = 45,000
(L)
(D)
For parts positioned at the center of the coil:
Where:
NI = 43,000 R
( 6L ) - 5
( D)
I = Coil peak current to be used (amperes)

N = Number of turns in the coil R = Coil Radius
L = Part length
D = Part diameter
* NOTE: If a part is longer than 18 inches, L/D shall be calculated using a value o L
= 18, and D = Actual Diameter. If the resulting value of L/D is between 2 and 15, that
calculated value will be used in the equations located on the preceding page.
If the resulting value of L/D is greater than 15, a value of 15 shall be used in the
equations located on the preceding page.
If the resulting value of L/D is less than 2, the part will be inspected using an
alternate approach.
When calculating the L/D ratio for a hollow part, D shall be replaced with an effective
diameter,
Deff' calculated using:
-
(At Ah)
Deff' = π
\
Page 4-14
Where: At = the total cross-sectional area of the part

Ah = the cross-sectional area of the hollow portion of the part.
For cylindrical parts, Deff is equivalent to:
Deff = √ (OD)2 - (ID)2

Where: OD = the outside diameter of the cylinder
ID = the inside diameter of the cylinder
Separate magnetizing operations shall be used for both circular and longitudinal
magnetization when parts contain changes in sections that differ by more than 30
percent. In such cases, the sequence of magnetization shall begin with the lowest
current level and proceed in the direction of higher currents. For circular magnetization,
the peak field strength of each section shall be maintained in the range of 30 to 60
gauss. Proper care shall be taken to avoid damage to smaller sections from
overheating.
Residual magnetization shall be used when required by Drawing or program document
4.2.7.11Magnetization (As per BS 6072)

4.2.7.11.1 Current Flow
The effective value of current in MPI is the peak value. However, it is impractical to use
ammeters which are responsive to the peak value, hence it necessary to use instruments
which response either to root mean square (rms) or to the mean value, and to calculate
the peak from the known or estimated waveform.
The following table shall be used to determine indicated current values for the
various methods of magnetism. Each machine in use shall be clearly marked with
correction factors allowing conversion from peak to indicated and vice versa.
Full Wave Half Wave

Current Waveform DC Source Ac Source
Rectified Rectified
(Amp) (Amp)
(Amp) (Amp)
Current for basically round 28 20 18 9
parts per mm diameter
Current for non-rounded 9 6.4 5.7 2.9

parts per mm circumference
For Threading Bar application, where the bar is concentric with the part, the current value
shall be calculated from the above table, based on the outside diameter of the part. In
cases where the Threading Bar cannot be mounted concentric with the part, it shall be
positioned away from the axis. The current value shall be calculated from the above table
by taking the diameter of the circle centered on the Threading Bar with the outer surface
of the part on its circumferences. In such cases the part shall be tested in stages to ensure
360°C coverage
Page 4-15
The central conductor used shall be covered with an insulating material, or non-
conductive spacers to ensure that components do not touch the threading bar to
avoid a danger of burning
To test parts of varying diameters some compromise is necessary regarding the
current used. When the largest diameter exceeds the smallest diameter by 50% or less,
then the average of the currents normally required may be used to test the whole part
(e.g. a part having diameters of 100mm and 75mm could be given are shot to test the
whole length) calculated as follows:
100.0 at 20 amps AC per mm = 2,000 amps AC
75.0 at 20 amps AC per mm = 1,500 amps AC
3,500 amps
Average current = 3,500 = 1,750 amps AC

2
Where the largest diameter exceeds the smallest diameter by more than 50% then more
than one shot is required. A higher current than that required for test may be passed
through the smaller diameter, in order to test the larger diameter providing due
precautions are taken against burning and overheating and that defect indications are
evaluated at the correct testing amperage for each diameter (e.g. a part made up of
25mm, 50mm and 100mm diameters would require three separate testing shots of current
flow):
Shot 1: 25 at 20 amps AC per mm = 500 amps AC

Shot 2: 50 at 20 amps AC per mm = 1,000 amps AC
Shot 3: 100 at 20 amps AC per mm = 2,000 amps AC
4.2.7.11.2 Coil
The peak current shall be calculated from the formula:
NI = K
L/D
Where:
N = Number of turns
I = Current
L = Length of part
D = Diameter of part
K = 32,000 for DC and peak value of any wave for
K = 30,000 for AC (r.m.s value)
Where the part length diameter L/D ratio is less than 5:1, extenders shall
be used to extend the length of the flux path. If the L/D ratio is greater
then 20 then the value 20 shall be substituted for L/D.
4.2.7.12 Symbols and Abbreviations
The following symbols and abbreviations shall be use in the MPI instruction.
Page 4-16
Type of test Abbreviation Symbol
Magnetic Flow MF MF [ ] MF
Current Flow CF CF CF
TB TB
Central conductor
Coil COIL COIL
4.2.7.13 Pre-inspection
4.2.7.13.1 Demagnetization
The part shall be demagnetized before examination if prior operations have
produced a residual magnetic field that may interfere with the examination
4.2.7.13.2 Surface Cleanliness and Finish
The surface of the part to be inspected shall be essentially smooth, clean, dry and free of
oil, scale, machining marks, or other contamination or conditions that might interfere
with the efficiency of the inspection. After cleaning parts shall be inspected as soon as
possible to reduce the possibility of corrosion. In all circumstances they shall not remain
unprotected for a period exceeding 24 hours"
4.2.7.13.3 Coating
1. Magnetic particle examination shall not be performed with coatings of paint or
chrome plated greater than 0.08mm (0.003 in) in thickness and ferromagnetic
coatings such as electroplated nickel greater than 0.03mm (0.001 in) in thickness.
2. Nonconductive coatings must be removed when electrical contact is to be
made.
4.2.7.14 Inspection Procedure

4.2.7.14.1 The suspension shall be circulated for at least 30 minutes before the testing begin.
4.2.7.14.2 White light shall be no more than 1 foot candles (10 lux) in the inspection booth with the
black lights illuminated and warmed up.
4.2.7.14.3 Black light intensity shall be a minimum of 1500 µwatts per cm2 at 15 inches from the face
of the light lens filter. Wavelength of the black light shall be in the range of
3200 to 4000 angstroms.
4.2.7.14.4 The UV light shall be allowed to warm up a minimum of 5 minutes before use for
inspection.
4.2.7.14.5 Allow 1 minute for dark adaptation of the eyes before beginning the inspection.
4.2.7.14.6 Inspectors shall not wear eyeglasses with light sensitive (photo chromatic) lenses
Page 4-17
4.2.7.14.7 For all positions, suspension shall be applied to the part until all surfaces requiring
inspection are thoroughly covered.
4.2.7.14.8 All AESC originated instructions shall be controlled by gauss meter readings, which
shall take precedence over calculated current readings.
4.2.7.14.9 Immediately after diverting the suspension, the part shall be magnetized at the appropriate
amperage with two current pulses of approximately ½ second duration.
4.2.7.14.10 Parts shall be inspected for discontinuity indications using a X 5 to X 10 magnifier and the
locations of the discontinuities shall be marked on the part.
4.2.7.14.11 Visual aids such as mirrors and borescopes shall be used when geometric configuration
prevents surfaces from being visible with ± 30º of the normal (90º) viewing angle.
4.2.7.14.12 Demagnetization Procedure
All parts shall be demagnetized as follows:

1. With the coil energized, the part shall be held about one foot in front of the AC
demagnetizing coil and then moved slowly through the coil to a point three feet
beyond it when the current will be stopped.
2. Parts of complex configuration shall be rotated and tumbled while passing
through the energized coil.
3. This process shall be repeated as necessary until field indicator shows the
residue magnetism of the parts is within ± 3 gauss.
4.2.7.14.13 Post Cleaning

Parts shall be thoroughly cleaned before proceeding to the next process. Those parts
containing discontinuity indications shall be marked. After cleaning parts shall be
inspected as soon as possible to reduce the possibility of corrosion. In all circumstances
they shall not remain unprotected for a period exceeding 24 hours"
4.2.8 Instruction Detail

4.2.8.1 Unless otherwise authorized, components shall be magnetic particle inspected using the
process by approved AESC instructions.
4.2.8.2 Instructions for magnetic particle inspections shall take the form of:
1. Airworthiness Directives
2. Service Bulletin
3. AESC NDT Instructions (generic or specific)
4.2.8.3 Level 1 certified inspector should not carry out an inspection without reference to an
instruction as defined above (ADs, SBs or local instructions). All AESC NDT instructions
shall be approved by the responsible Level 3. Level 1 inspectors shall be trained by a
Level 2/3 on AD, SB and Instruction compliance, as necessary to ensure competence prior
to exercising independent inspections.
Page 4-18
4.2.8.4 AESC NDT Instructions shall be written to be understood by a Level 1 inspector and shall
include the elements listed below as a minimum.
a. An unique reference number
b. Purpose of the test
2. Personnel: The minimum level of certification required to apply the instruction

3. Apparatus to be used: Equipment to be used together with settings
4. Product/area to be tested Component identification, brief description and a
drawing if appropriate
5. Test conditions:
a. Pre-test preparation of the test area
b. Post test cleaning and preservation of test object
a. All instructions shall state the “type” of current applied for the inspection for
each applicable component (e.g. AC, HWR, 3 Ph FWR, etc,.)
b. All instructions shall identify the required current both numerically and by the
term “Peak” unless otherwise required.(Note: The instruction may otherwise
identify the actual meter reading as “Indicated” where the equipment shall be
identified by model no. and operator confusion is potentially reduced.).
c. Where an instruction is established using a gauss meter reading for current
selection, then the gauss meter probe location and orientation shall be clearly
marked on a drawing of the part and incorporated into the instruction
d. Step-by-step instructions in the application of the NDT technique with

reference to sketches if appropriate
e. A statement instructing the inspector on actions to be taken in the event that
7. Recording and classifying results: Action to be taken when defect are detected.
9. Assessment of Test Results: The instruction must specify the minimum size and
type of indication sought and applicable, the method of classification and sizing to
be employed.
Page 4-19
10. Reporting of Test Results:

Reports of inspection results shall be in accordance with Aerospace Engineering
Services JSC standard maintenance inspection procedures. Where requested by QA,
normally on location of a rejectable flaw, the Head of NDT may be asked to
generate a detailed report. Such a report shall contain the following information
headings as a minimum and each shall have a detailed narrative with accompanying
digital images and drawings as required.
a. Ad, SB, Procedure/Instruction Reference
b. Component part number, serial number, aircraft registration c.
Equipment used with serial number
d. Equipment settings
e. Defect location, size and description
f. Status of indications, “Rejectable”, “Acceptable”, “in limits” etc. g.
Inspector’s name and qualification
h. Inspector’s signature, Head of NDT’s signature
11. Non-compliance Statement: Any inspection that cannot be completed for technical
reasons beyond the control of the inspector shall be reported to be Head of NDT for
investigation.
4.2.9 Reporting
4.2.9.1 The result shall be reported. All indications shall be reported, quoting the length and
position on the sketch.
4.2.10 Maintenance
4.2.10.1 Daily
1. Remove and clean sump screen
2. Check headstock, tailstock and coil and cable connections. Tighten as
necessary
3. Check headstock clamp
4. Check coil and tailstock locks
5. Check tank, hoses and nozzle for leakage
6. Check air cylinder, fitting, hoses, air regulator and speed control valve
7. Check bulbs and meter readout
8. Check for smooth and proper operation of all pushbutton, toggle and selector
switches and CURRENT CONTROL potentiometer
9. Check for missing or broken filter of black light
10. Repair small cuts and tears of curtain with black plastic electrical tape
Page 4-20
4.2.10.2 Weekly
Open valve and blow out moisture from air filter bowl
4.2.10.3 Monthly
1. Clean the tank, grills and sump screen using dry cleaning solvent. After
cleaning, flush parts with appropriate bath solution.
2. When water bath is used, remove oxidation from between the contact pad and
contact plate use a wire brush/emery paper.
3. Clean air filter element and bowl
4.2.11 Appendices
Appendix A: UV, White & visible light intensity record, internal short circuit check
record (FORM-MT01)
Appendix B: System performance record – Tool Steel Ring record, Coil
Magnetization, Tool Steel ring specimen indication (FORM-MT02)
Appendix C: Maximum and minimum coil, head shot current output record (FORM-
MT03)
Appendix D: Instruction sheet for electromagnetic yoke and Permanent Magnet

(FORM-MT04)
Page 4-21
Examining the testing agent / suspension
1. Brilliance of fluorescent:
Make a comparison between a standard sample of 'unused' testing agent and 'used' testing agent
under black (UV) light for brilliance of particle fluorescence.
2. Discoloration
Check the contamination of the suspension for clarity and absence of yellow fluorescence under
black light. Check for lint, dirt or scale.
3. Concentration
a) Run the pump for at least 30 minutes and at the same time thoroughly agitate and mix by
hand all suspension which have settled upon the screen and along the bottom of the tank.
b) Fill centrifuge tube to the 100ml mark with suspension directly from the hose.
Demagnetize the suspension and allow the suspension to stand for 60 minutes for oil based
or 30 minutes for water based to settle.
c) Read the volume of the settled suspension in the tube. Settlement flask shall lie within the
following: Fluorescent ink – 0.1 to 0.3ml
d) If the suspension is low in particle content, brush tank bottom to lift particles or add
magnetic particle to obtain the required concentration.
e) If the suspension is high in particle content, add fluid to obtain the required
concentration.
4. Contamination
* THE SAME SAMPLE AS IN (3) CHECK FOR THE FOLOWING *
a) Examine the liquid above the precipitate with black light. The liquid shall not fluoresce. b)
Examine the precipitate. If two distinct layers can be seen, read the volume of each
layer. The top layer volume (contamination) shall not exceed 10% of the bottom layer
volume and the contamination layer shall not fluoresce.
Page 4-22
APPENDIX A
CONTROL SHEET FOR LIGHTING & INTERNAL SHORT CIRCUIT (FORM-MT01)
DAILY CHECK OR BEFORE INSPECTION CHECK
REFERENCE: MAGNETIC PARTICLE INSPECTION PROCEDURE NO: AESC/NDT/PR/MT02
MAGNETIC BENCH MODEL NO: MONTH AND YEAR:
BLACK LIGHT S/N:
UV METER: P/N: S/N:
VISIBLE METER: P/N: S/N:
Black Light (UV) Weekly Check

White Light Visible Light
Date Intenstiy Internal Short Sign.
Intenstiy Intenstiy
Circuit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Page 4-23
Inspection Station
1. UV Light Intensity
a) Expose the sensor cell of the UV intensity meter to the black light.
b) Read off the scale
c) The scale shall be not less than 1500 µW/cm2 at the part being examined where the
distance between the UV light filter and UV light intensity meter shall be not less
than 381mm (15 inches). The wavelength of the black light shall be in the range of
3200 to 4000 Angstrom.
2. White light Intensity
a) Expose the sensor cell of the light intensity meter to the visible light with all
adjacent black lights turned “on”.
b) Read off the scale.
c) The white light intensity shall not exceed 1 fc (10 lux) measured at the inspection
surface with black light at 15 inches from the inspection surface.
3. Visible Light Intensity
Visible light shall be used when examining with non fluorescent magnetic particles and for
interpretation of indications found with fluorescent magnetic particles. a minimum light
intensity of 100fc (1000 lx) shall be available at the surface of the part undergoing
examination or evaluation.
4. Internal short circuit check
Set for maximum amperage output. Set for “Head Shot”. Any deflection of the ammeter
when the current is activated with no conductor between the contacts is an indication of
an internal short circuit.
Page 4-24
APPENDIX B
CONTROL SHEET FOR SYSTEM PERFORMANCE CHECK (FORM- MT02)

MAGNETIC BENCH MODEL NO:
TOOL STEEL RING: P/N: S/N:
MONTH AND YEAR:
No of holes related to current Hole Indication of Coil QQI

Sign.
Date flow amps Magnetizatio Indication
500A 1000A 1500A 2500A 3500A 1250A (AC) nnnn1500A (DC)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Page 4-25
System Performance Check.
1. Current Flow – Tool Steel Ring.

a) Use a 1" to 1 3/16" diameter copper bar with 16" to 24" length for the Tool Steel
Ring check.
b) Place the conductor through the centre of the Tool Steel ring. c)
Centre the Tool Steel ring on the length of the conductor.
d) Magnetize the Tool Steel ring circularly by passing the current specified in
Annex I through the conductor.
e) Apply the suspension to the Tool Steel ring using the continuous method.
f) Examine the Tool Steel ring within 1 min after current application under a black light
of not less than1500 µW/cm2
g) The number of the hole indications shall meet or exceed those specified below and
QQI shall be clear at each current setting indication.
Table 2: Amperage and hole indication for TOOL STEEL RING from initial test
(ANSI 01Series Tool Steel or Contromag 10052)
Amperage Number of holes

Type of suspension indicated
(FWDC OR HWDC)
500 3
1000 5
Fluorescent oxide(wet) 1500 6
2500 7
3500 9
2. Coil Magnetization (Test piece [TBD]).

a) Place the coil test piece at the centre of the coil.
b) Observe the 3 transverse hole indications AC and 4 transverse hole indications
DC show at the middle of the test piece.
c) The indications show that the coil magnetization is good condition.
Page 4-26
APPENDIX C
COIL CURRENT & HEAD SHOT CURRENT OUTPUT (FORM- MT03)
MAGNETIC BENCH MODEL NO:
MAGNETIC BENCH S/N:
MAGNETIC BENCH LOCATION:
CHECK EVERY 6 MONTH:
MACHINE AMMETER NEXT DUE DATE:
COIL CURRENT OUT PUT HEAD SHOT CURRENT OUTPUT
MIN CURRENT
OUTPUT MAX CURRENT MIN CURRENT MAX CURRENT
OUTPUT OUTPUT OUTPUT
DATE:
SIGN.
Page 4-27
1. Maximum and minimum coil current output

Set the controls for the machine to the maximum and minimum current value. Pulse the
current.
2. Head shot current output (Electrical Capacity)
Output at minimum and maximum shall be determined, with a one (1) inch diameter
copper bar, 18 inches long between the head or electrodes. Ensure contact at ends is
good.
Page 4-28
APPENDIX D
INSTRUCTION SHEET FOR ELECTROMAGNETIC YOKE (FORM-
MT04)
Note: this instruction requires familiarization with technique and tools.

This instruction is used only when other instructions are not available, i.e. NDTSPM, T.O., S.I.D. or
approved documents for Maintenance programmes.
TOOLS :
Electromagnetic Yoke
Prepared Bath 14AM spray aerosol fluorescent suspension ready to use
ARDROX 9PR5 solvent aerosol cleaner/remover
black light
Gauss meter
White light meter
Duty Cycle for P/N [TBD]:

Maximum ratio is [TBD] “ON”, [TBD] “OFF”
Heating of the coil cover is an indication of excessive time “ON”.
Do not change the AC/DC selector switch with the unit in operation, or damage may result to the
switch.
Magnetization Function AC/DC :

Use AC only for surface inspection (induce into part surface field). Do not use for residual
method.
Use DC for surface and sub-surface inspection
Unless otherwise specified, use DC current.
Turn Probe of 90° from the first test (two perpendicular magnetization is necessary).
Demagnetization:
Perform demagnetization in AC mode, place switch between pole pieces and withdraw to a
distance of 2-3 feet before turning probe off.
On large pieces, place Probe in the same position used for inspection, turn probe on and lift from
work to a distance of 2-3 feet before turning off.
Verify that max residual gauss leakage on the part does not exceed 3 Gauss.
Procedure:
1. The area of interest must be stripped unless otherwise stated.
2. Clean the area of interest as required.
3. Darken the inspection area and verify white light at inspection surface does not exceed 20
Lux (2 fc).
Page 4-29
4. With the probe set in either the AC or maximum DC position, place pole pieces upon work with
the suspected defect at right angles to poles, adjust pivot probe for best contact on the
interested part.
5. Push test switch and lightly spray inspection suspension over area being inspected.
6. Using the ‘wet continuous’ method, test switch should be held continuously when applying
inspection suspension.
7. With black light, inspect area ensuring black light intensity exceeds 1500µW/cm² at the
inspection surface.
8. If an indication is found, evaluate as non-relevant, relevant or spurious and mark relevant
indication on the part. Demagnetize area, check for residual magnetization and complete
defect report.
9. If indication is not relevant or no indications are found, demagnetize area, verify residual
leakage magnetization if it is within +/- 3 Gauss, and clean the area.
10. Repeat all preceding steps for all areas to be inspected
11. Apply protective treatment.

PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/PR/PT02
4.3 PENETRANT INSPECTION PROCEDURE

4.3.1 Scope
1. This procedure establishes the AESC minimum requirements for
conducting liquid penetrant inspection of nonporous metal, and non-metal
components.
2. The penetrant examination processes described in this procedure are
applicable to in-process, final, and maintenance (in-service) inspections.
4.3.2.1 The following documents form a part of this practice to the extent specified
herein.
1. NAS 410 to latest revision - Certification and Qualification of Nondestructive
Test Personnel.
2. EN 4179 to latest revision - Qualification and Approval of Personnel for Non-
destructive Testing.
3. AESC Written Procedure No: AESC/NDT/MANUAL/002 - Qualification and
Certification of personnel for NDT.
4. ASTM Standards
a. ASTM E1417
b. E165 - Test Method for Liquid Penetrant Examination
c. E 1135 - Test Method for Comparing the Brightness of Fluorescent
Penetrants
5. Standard Practice Manual 32-09-01 section 38 & 39 (Messier Bugatti)

6. GOODRICH NDT Manual 32-40-76
4.3.2.2 Order of Precedence – In the event of conflict between the text of this procedure and
AESC references cited herein, the text of this procedure takes precedence. In the event
of conflict between the text of this procedure and OEM or Aviation Authority
references cited herein and aircraft maintenance practices, the text of OEM, Aviation
Authority or aircraft maintenance procedures takes precedence
4.3.3 Definitions:
4. NDT Code or Specification: a public document controlling standards of NDT
application e.g. EN4179, Aircraft NDT Manuals, ASTM Standards.

6. Component: the part(s) or element(s) of a system described, assembled, or

processed to the extent specified by the drawing.
7. In-service: refers to components that are in use or storage for their intended
function
8. Linear indication: magnetic particle indications with at least a three to one
length to width ratio.
9. Reprocess: repeat, after cleaning, the application and appropriate
processing of magnetic particle inspection (as required).
4.3.4 Significance and Use
1. This procedure establishes the AESC basic parameters for controlling the
application of the penetrant flaw detection method.
2. Safety. There are no special safety precautions related to this method.
However inspectors should be aware of standard electrical safety practices within
AESC including operations in and around the facility and the risk of particle/fume
inhalation for this method.
4.3.5 Classification
4.3.5.1 Penetrant systems covered by this procedure shall be of the following types,
methods, and sensitivity levels.
4.3.5.1.1 Type:
1. Type I – Fluorescent dye
2. Type II – N/A
4.3.5.1.2 Method
1. Method A – Water washable
2. Method B – N/A
3. Method C – Solvent-removable
4. Method D – Post-emulsifiable, hydrophilic
4.3.5.1.3 Sensitivity
1. Sensitivity Level ½ - very low
2. Sensitivity Level 1 – low
3. Sensitivity Level 2 – Medium
4. Sensitivity Level 3 – High
5. Sensitivity Level 4 – Ultra high
4.3.5.2 Developers shall be of the following forms:
1. Form a – Dry powder
2. Form d – Nonaqueous for Type I fluorescent penetrant
4.3.5.3 Solvent removers shall be of the following classes:
1. Class1- Halogenated
2. Class 2 – Nonhalogenated
Page 4-32
4.3.6 General Practices

1. Responsibility for NDT Examinations - Unless otherwise specified by the
Original Equipment Manufacturer (OEM) or recognised aviation authority, AESC is
responsible for the performance of all NDT examination requirements as specified
herein.
2. Specifying – When NDT examination is required in accordance with this
procedure, instructions, ADs and SBs shall specify the criteria by which the
acceptability of components is to be evaluated. In any other cases appropriate
generic NDT instructions shall be used and shall define or specify objective
reject criteria.
3. Personnel Qualification – Personnel performing NDT examinations to this
practice shall be qualified and certified in accordance with the AESC Written
Procedure No: AESC/NDT/MANUAL/002 which complies with the requirements of
NAS 410/EN4179.
4. Agency Qualification - N/A
5. Qualified Materials – Only materials from customer-approved suppliers may be
used.
6. Equipment and Facilities – Processing equipment used in the penetrant
examination process shall be constructed and arranged to permit a uniform and
controlled operation. The equipment shall meet all applicable national and local
safety requirements as well as the requirements specified herein.
7. Viewing Areas – Areas where parts are reviewed shall be kept clear at all times.
For stationary fluorescent dye examination, Type I, the ambient visible light
background shall not exceed 5 lux at the examination surface. The black
lights shall provide a minimum of 1500 µW/cm² at the examination surface. Black
lights shall meet the requirements of 4.3.7.8.4 A. Viewing areas for portable
fluorescent dye examination shall utilize dark canvas, photographer’s black cloth,
or other methods to reduce the visible light background below 5 Lux during
examination and black light intensity shall meet the above requirements.
8. Drying Oven – When components are oven dried, the dryer must be a
forced-air recirculating type. The temperature shall be controlled with a calibrated
device capable of maintaining the oven temperature at ±15ºF of the
temperature for which it is set. The oven shall not exceed 160ºF (71ºC). The
temperature indicator shall be accurate to ±10ºF of the actual oven temperature.
9. Written Instructions – All liquid penetrant examinations instructions are
similar for many components. Master written instructions shall be utilized that
cover the solvent removable water washable and post emulsified processes as
separate techniques.
10. Examination Sequence – Final penetrant examination shall be performed after
completion of all operations that could cause surface-connected discontinuities.
11. Surface Coatings – All coatings and other surface conditions, such as paint, plating,
corrosion etc. shall be removed from the area to be examined prior to penetrant
examination.
12. Material and Process Limitations
Page 4-33
a. Type II penetrant examinations are not approved for use for the
maintenance or overhaul of aircraft including the examination of turbine
engine critical components. These inspections shall be done only with Type
I, Methods C or D (solvent removable or post emulsified, hydrophilic)
processes and either sensitivity Levels 3 or 4 penetrant materials.
b. The maintenance or overhaul examination of turbine engine critical
components shall be done only with Type I, Methods C or D (solvent
removable or post emulsified, hydrophilic) processes and either
sensitivity Levels 3 or 4 penetrant materials.
4.3.7 Specific Practices (Fig 1)
CLEANING
APPLY PENETRANT
REMOVE PENETRANT
WHEN USING NONAQUEOUS & DRY

DEVELOPERS
DRY PARTS
APPLY DEVELOPER
EXAMINE PARTS
POSTCLEANING
(FIG.1)
4.3.7.1 Surface Preparation – All surfaces to be examined shall be clean, dry, and free of soils,
oil, grease, paint and other coatings, corrosion products, scale, smeared metal,
welding flux, chemical residues, or any other material that could prevent the
penetrant from entering discontinuities, suppress dye performance, or produce
unacceptable background. After cleaning, parts shall be inspected as soon as
possible to reduce the possibility of corrosion. In all circumstances they shall not
remain unprotected for a period exceeding 24 hours.
4.3.7.2 Penetrant Application – Unless otherwise specified, the entire surface of the
component shall be covered with penetrant. The component, penetrant, and ambient
temperatures shall all be in the range from 40ºF to 125ºF (4ºC to52ºC) unless otherwise
specified.
Page 4-34
1. Penetrant Dwell Time – The dwell time, unless otherwise specified, shall be a
minimum of 10 minutes. For temperatures between 40ºF and 50ºF (4ºC and
10ºC), dwell time shall be a minimum of 20 minutes.
4.3.7.3 Penetrant Removal

1. Method A Process shall be carried out in accordance with written instruction
2. Method B Process is not applicable to this procedure.
3. Method C Process shall be carried out in accordance with written instruction
4. Method D Process shall be carried out in accordance with written instruction.
4.3.7.4 Drying – The components shall be dried prior to the application of dry developer.
1. Drying Parameters – Components shall be air-dried at room temperature or in a
drying oven. Oven temperatures shall not exceed that specified in paragraph
4.3.6.8. Drying time shall only be that necessary to adequately dry the part.
Component shall be removed from the oven immediately after drying.
4.3.7.5 Developing – Unless otherwise specified, developers shall be utilized for
penetrant examination. Components that are not inspected before the maximum
bleed out time shall be cleaned and reprocessed.
Note: When the extraction system affects the even coverage of the part with
developer, it shall be switched off until application of developer has been completed,
and then switched on to clear particles air suspended.
1. Dry Developers – Components shall be dry before the developer is applied.
Dry developer shall be applied in such a manner as to contact all surfaces to be
inspected. Excess dry developer may be removed after the development time by
light tapping or light air blow-off not exceeding 5 psi and at a distance not
less than 30 mm (11.81in). Minimum and maximum developer times shall be 10
minutes and 2 hours respectively.
2. Non-aqueous Developers – Components, or areas requiring examination, shall
be dry before application of the developer. Non-aqueous developer shall be
applied by spraying. The developer shall be applied as a uniform thin coating
over the entire surface to be inspected. Unless otherwise specified, the minimum
and maximum development times for non-aqueous developers are 10 minutes
and one hour respectively. The developer container shall be frequently agitated
during application.
4.3.7.6 Inspection – The inspection area shall meet the appropriate requirements of
paragraph 4.3.7.8.4. Direct viewing shall be accomplished normal to the surface (±
30°). Components shall be inspected before the maximum developing time.
Components not inspected before the maximum developing time shall be cleaned and
reprocessed.
Page 4-35
1. Type I Processes – Inspector’s vision shall be dark adapted for a minimum of 1

minute prior to examining components. Longer times for more complete
adaptation should be used if necessary. Inspectors shall not wear photochromic or
permanently darkened lenses while processing or reviewing parts under black
light. Black lights shall meet the requirements of paragraph
4.3.7.8.4 A. All areas of fluorescence shall be interpreted. Component with no
indications or only non-relevant indications shall be accepted.
2. Components with relevant indications shall be evaluated with respect to the

applicable acceptance criteria. Components with excessive background
fluorescence shall be cleaned and reprocessed.
3. Type II Processes – not applicable to this procedure.
4. Evaluation – All indications found during inspection shall be evaluated at the

normal angle to the surface (± 30°) in accordance with specified acceptable
criteria after a period of at least 3 minutes eye adaptation time.
5. Indication Verification – Indications may be evaluated by wiping the
indication with a solvent-dampened swab or brush, allowing the area to dry, and
redeveloping. Redevelopment time shall be at least ten minutes; nonaqueous
redevelopment shall be three minutes minimum. If no indication reappears, the
original indication is considered false. This procedure will be performed only once
for any given original indication.
6. Sizing – If the acceptance criteria are written in terms of indication sizes, the
indication size shall be measured as development time has elapsed. If the
acceptance criteria are written in terms of discontinuity or flaw sizes, the
discontinuity shall be measured.
4.3.7.7 Post-cleaning – Components shall be cleaned after examination to remove

developers and other examination material residues. After cleaning parts shall be
inspected as soon as possible to reduce the possibility of corrosion. In all circumstances
they shall not remain unprotected for a period exceeding 24 hours.
4.3.7.8 Quality Control Provisions – This section provides the controls necessary to ensure
that the penetrant system, materials and equipment provide an acceptable
level of performance. The frequencies of the required checks in Table
1 are based on AESC operating daily. For situations operating less frequently, the
frequency of daily and weekly checks and those required at the start of each shift may
be reduced accordingly but must be performed prior to processing of parts. Monthly
and quarterly checks shall be performed at the same frequency as for full-time
operations. The AESC may perform these process control operations or contract for
their performance with an independent laboratory. Records of tests, except as noted
in Table 1, shall be maintained and available for audit by the aviation authority or
regulatory agencies. Penetrant materials that are provided ready-for-use and do not
require mixing to a concentration, and are not recovered, or reused, or both, such as
materials packaged in aerosol containers, closed drums or materials poured into
containers for use and are not reused, are not subject to the in-use penetrant
requirements.
Page 4-36
1. New Material Conformance – Prior to being placed into use, the

conformance of materials to requirements of the customer shall be verified,
usually by a certified report from the supplier. Additionally, a sample of each
penetrant material shall be retained separately for comparison tests. These
extracted samples shall be stored in darkness when not being used
2. Material Checks (in-Use) – The applicable tests specified in 4.3.7.8.2 A.
through 4.3.7.8.2 E. shall be conducted on in-use materials at the intervals
specified in Table 1.
a. Penetrant contamination – The in-use penetrant materials shall be
viewed as specified in Table 1 to determine if any of the following conditions
are evident: precipitates, waxy deposits, white coloration, surface scum, or
any other evidence of contamination or breakdown. When any of the above
conditions are detected, the material shall be discarded or otherwise
corrected, as appropriate.
Note: This test is not necessary when fresh penetrant is applied as a total
loss from an enclosed container via spray to waste.
b. Penetrant colour intensity – colour intensity checks of the in-use
fluorescent shall be made against a standard of unused penetrant .this check
shall be carried out on penetrant material irrespective of the application
method. Checks shall be in conducted at the intervals specified in Table 1. A
filter paper shall be soaked with the penetrant under test and another in an
unused sample. Dry both sample in an air circulating oven for five minutes at
a temperature not exceeding 71°C. and compare under a UV source. If there
is a visual difference in fluorescent between the two samples, further check
shall be carried out. Refer to Penetrant brightness checks.
c. 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 for each sample
and a minimum of 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.
Page 4-37
d. Water content of water-based water-washable Penetrants – The water

content of water-based Method A Penetrants shall be checked at the
intervals specified in Table 1 using a refractometer. The water content must
be maintained according to the manufacturer’s recommendation.
loss from an enclosed container via spray to waste
e. Water content of non-water based water-washable Penetrants shall be
checked at the intervals specified in Table 1 in accordance with test method
D 95 or Karl Fischer as described in Appendix C page 2. If the water content of
the in–use penetrant exceeds 5%, the penetrant shall either be discarded or
sufficient unused penetrant added to reduced the water content to below 5%.
loss from an enclosed container via spray to waste.
f. Hydrophilic Emulsifier Concentration - Concentration of the emulsifier
solution shall be checked at the intervals specified in Table 1 using a
refractometer. Refractometer values obtained shall be compared to actual
values obtained from known concentrations of emulsifier. For immersion
applications, the concentration, as a percent of volume, shall be no higher
than that specified by the penetrant system supplier and shall not exceed
10%.
g. Dry Developer Condition - Recycled or reused dry developer shall be
checked as specified in Table 1 to check for fluorescence and to ensure it is
fluffy and not caked. To check for fluorescence, apply a thin layer of in-use
developer to a 4-inch diameter or greater size flat test panel using the same
method of application used for production parts, and observe under a black
light. Dry developer exhibiting ten or more fluorescent specks in a 4-inch (10
cm) diameter circle is unsatisfactory and shall be replaced. Where fresh
developer is used for each application such as electrostatic spray to waste,
the developer shall be checked each time the bulk container is filled.
3. Penetrant system performance – the penetrant system’s overall performance shall

be checked as specified in Table 1. The check shall be performed by processing a
known defect standard through the system. The chemistry shall be in-use
penetrant, emulsifier (if used), developer and appropriate processing parameters.
The resulting indications will then be compared to the indications previously
obtained using unused penetrant, emulsifier (if used) and developer. This
comparison shall be made with a full size photograph of previously obtained
indications originated per the Appendices to this procedure or with a similar
known defect standard processed with unused materials from a hold-out sample.
When the sensitivity or performance of the in-use materials falls below the
performance of the unused materials, the in-use materials shall be checked in
accordance with paragraphs 4.3.7.8, 3b, 3c, and 3d below.. Unacceptable
materials shall be discarded or otherwise corrected in accordance with the
manufacturer’s instruction.
Page 4-38
a. Known Defect Standards – The known defect standard used shall be

approved by the Level III. There shall be a pair of standards per
penetrant technique and each pair of standards shall be dedicated for one
technique only. AESC shall establish and document effective cleaning
instructions based on the defect standard manufacturer’s instructions. The
user shall ensure that cleaning of the standards between uses is
adequate and that physical changes in the standard that make it
unrepresentative if the indications found using the hold-out sample are
detected. This shall be achieved by making a careful comparison of the star
patterns on the standard with the star patterns on the photograph, and the
“not-in-use” TAM panel. If any deterioration is noted, the panel shall be
ultrasonically cleaned until a satisfactory comparison is made, or the panel
should be replaced..
b. 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.
loss from an enclosed container via spray to waste
c. 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.
d. 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.
Page 4-39
Note: This test is not necessary when fresh penetrant is applied as a total loss from an enclosed
container via spray to waste.
4. Equipment Checks – The following equipment checks shall be conducted at the

intervals specified in Table 1.
a. Black Light – Portable, hand-held, permanently mounted or fixed black
lights used to inspect parts shall be checked for intensity as specified in Table
1 or prior to use, and after bulb replacement. The minimum acceptable
intensity is 1500 µW/cm2 at 15 in. (38.1 cm) from the front of the filter to the
face of the sensor. Black lights shall be checked at the intervals specified in
Table 1 for cleanliness and integrity and shall be cleaned or repaired or
replaced as appropriate.
b. Visible Lights – The white lighting system shall be available at the
inspection area and checked at intervals specified in Table 1 to ensure a
minimum of (2500 lux) when measured at the examination surface.
c. Light Meters – Ultraviolet and visible light meters shall be calibrated at
intervals specified in Table 1.
d. 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.
e. Water Wash Operating Pressures/Temperatures – Indicators and
controls shall be checked as specified in Table 1.
f. Drying Oven Calibration – The temperature controlling device and the
temperature indicating device, if separate from the controller, on the
drying oven shall meet the requirements of paragraph 6.8 and shall be
calibrated at intervals specified in Table 1.
g. Timers – Timing devices used to measure or monitor processing times, such
as dwell times and eye adaptation times, need not be calibrated.
h. The water trap at the inlet of the planet pressure air network shall be
checked as specified in table 1, drain the trapped water when
necessary.
4.3.7.9 Marking and Identification – Components successfully passing the penetrant
examination shall be identified and marked by tagging which may be applied
when the construction, finish or functional requirements of the component preclude
etching, dyeing, or stamping. Items such as bolts, nuts, or other small parts may be
identified by conspicuously marking each package.
Page 4-40
Table 1 - Required Tests and Frequency

Tests Frequency Paragraph
Penetrant contamination A Daily 4.3.7.8.2 A.

Penetrant colour intensity test Weekly 4.3.7.8.2 B.
Penetrant brightness Quarterly 4.3.7.8.2 C.
Water content-
Weekly 4.3.7.8.2 D.
Water-based penetrant (Method A)
Monthly 4.3.7.8.2.E.
Non-Water-Based Penetrant (Method A)
Weekly 4.3.7.8.2.F.
Hydrophilic emulsifier concentration B
Daily 4.3.7.8.2 G.
Dry developer condition B Daily 4.3.7.8.3
Penetrant system performance C 4.3.7.8.3 B.
As required per 4.3.7.8.3
Water-washable penetrant removability 4.3.7.8.3 C.
Emulsifier removability 4.3.7.8.3 D.
Comparative penetrant sensitivity 4.3.7.8.4 A.
Daily
Black light intensity B Daily 4.3.7.8.4 A.
Black light integrity Daily 4.3.7.8.4 B.
Visible Light intensity Semi-annually 4.3.7.8.4 C.
Light meter calibration B Daily 4.3.7.8.4 D.
Inspection area cleanliness A Quarterly 4.3.7.8.4 D.
Inspection area ambient light intensity Start of each working shift 4.3.7.8.4 E.
Water wash pressure check A Water Semi-annually 4.3.7.8.4 E.
4.3.7.8.4 E.
pressure gage calibration B Water Start of each working shift
Semi-annually 4.3.7.8.4 E.
wash temperature check A Water 4.3.7.8.4 F.
Quarterly
temperature gage calibration B Daily 4.3.7.8.4 H.
Drying oven calibration B
Water trap at the inlet plant pressure air
network check A
A Need not be recorded

B The maximum time between verifications or checks may be extended when
substantiated by technical data and approved by the Level 3.
C Not required for Method C examination
Page 4-41
4.3.8 Appendices
4.3.8.1 Instruction for Initial Establishment of TAM Panel Reference Standards
4.3.8.1.1 Scope
This instruction shall be completed for each family system of penetrant processes
where one or more of the constituent process stages re-uses the chemistry.
4.3.8.1.2 Material
1. Each process technique shall have two dedicated TAM panels, which shall be
permanently identified with the process technique to which it is dedicated. Each
panel shall also be marked as either “reference” or “in-use”.
2. The “reference” panel shall be used once only to establish a “reference”
photograph for the process technique. The “in-use” panel shall be used for
daily/shift checks of the process technique. The photograph of the
“reference” panel shall be Taken under UV lighting matching the conditions
during inspection and reproduced in colour at full scale to the panel,
showing adequate resolution and contrast and placed in the viewing area
protected from contamination/ damage.
4.3.8.1.3 Process Technique Initial Application

The first process of the reference panel shall follow normal instructions with fresh
chemistry and the photograph shall be taken at the completion of the
development time. The reference panel shall then be cleaned and placed in store only
to be used if a photograph needs to be replaced.
4.3.8.2 Required Tests and Frequency
1. Appendix A: Control sheet for penetrant sensitivity (FORM-PT01)
2. Appendix B: Control sheet for developer & black, visible light (FORM-PT02)
3. Appendix C: Control sheet for water content of penetrant (FORM-PT03)
Page 4-42
Appendix A
CONTROL SHEET FOR PENETRANT SENSITIVITY (FORM-PT01)
DAILY CHECK
REFERENCE: PENETRANT PROCEDURE NO: AESC/NDT/PR/PT02
MONTH AND YEAR:
SENSITIVITY LEVEL 3
DAY TAM PANELS/N: SIGN

System performance Penetrant Contamination
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Page 4-43
Penetrant Contamination:
The in-use penetrant materials shall be viewed as specified in Table 1 to determine if any of the
following conditions are evident: precipitates, waxy deposits, white coloration, surface scum, or
any other evidence of contamination or breakdown. When any of the above conditions are
detected, the material shall be discarded or otherwise corrected, as appropriate.
Penetrant System Performance:
The penetrant system’s overall performance shall be checked as specified in Table 1. The check
shall be performed by processing a known defect standard through the system using in-use
penetrant emulsifier (if used) and developer and appropriate processing parameters. The resulting
indications will then be compared to the indications previously obtained using unused penetrant,
emulsifier (if used) and developer. This comparison shall be made with a full size photograph of
previously obtained indications or with a similar known defect standard processed with
unused materials from a hold-out sample. Unacceptable materials shall be discarded or otherwise
corrected in accordance with the manufacturer’s instruction.
Known Defect Standards – The known defect standard used shall be approved by the Level III.
There shall be a pair of standards per penetrant technique and each pair of standards shall be
dedicated for one technique only. A E S C shall establish and document effective cleaning
instructions based on the defect standard manufacturer’s instructions. The user shall ensure
that cleaning of the standards between uses is adequate and that physical changes in the
standard that make it unrepresentative of the indications found using the hold-our sample are
detected.
Page 4-44
Appendix B
CONTROL SHEET FOR DEVELOPER AND BLACK VISIBLE LIGHT (FORM-PT02)
DAILY CHECK OR BEFORE INSPECTION CHECK
REFERENCE: PENETRANT PROCEDURE NO: AESC/NDT/PR/PT02
MONTH AND YEAR: …………………….. BLACK LIGHT S/N:
UV LIGHT METER: P/N: S/N:
VISIBLE LIGHT METER: P/N: S/N:
Black Light Black Light Visible Light

Date Dry developer Sign
Intensity Integrity Intensity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
Page 4-45
Dry Developer Condition:

Recycled or reused dry developer shall be checked as specified in Table 1 to check for fluorescence
and to ensure it is fluffy and not caked. To check for fluorescence, apply a thin layer of in-use
developer to a 4-inch (10 cm) diameter or greater size flat test panel using the same method of
application used for production parts, and observe under a black light. Dry developer exhibiting
ten or more fluorescent specks in a 4-inch (10 cm) diameter circle is unsatisfactory and shall be
replaced.
Black Light:
Portable, hand-held, permanently mounted or fixed black lights used to inspect parts shall be
checked for intensity as specified in Table 1 or prior to use, and after bulb replacement. The
minimum acceptable intensity is 1500 µW/cm2 at 15 in. (38.1 cm) from the front of the filter to
the fact of the sensor. Black lights shall be checked at the intervals specified in Table
1 for cleanliness and integrity and shall be cleaned or repaired or replaced as appropriate.
Visible Light:
The white lighting system shall be available at the inspection area and checked at intervals
specified in Table 1 to ensure a minimum of (2500 lux) when measured at the examination surface.
Page 4-46
Appendix C
CONTROL SHEET FOR WATER CONTENT OF PENETRANT (FORM-PT03)
REFERENCE: PENETRANT PROCEDURES NO: AESC/NDT/PR/PT02
MONTHLY CHECK FOR

WATER CONTENT OF NON-WATER BASED PENETRANT (METHOD A)
Water Content of Non-Water Based

Date Sign.
Penetrant
(Method A)
Page 4-47
Water Content of non-water based penetrant:

Scope and Application - This modified Karl Fischer volumetric procedure is a practical
alternative to Test Method D 95 for undiluted hydrophilic emulsifiers and water
contamination of in-use lipophilic emulsifiers and Method A penetrants. The amount of
sample used is adjusted to meet the water equivalent capacity of the titration agent
employed (1 rnl = 5 mg H2O) For most materials required to meet the five percent (5%)
maximum allowable water content limit 0.5 to 1.0 g sample size is sufficient.
1. Apparatus:
Buret, glass, 50-ml,
Flask, wide-mouth Erlenmeyer type, 250-rnl,
Pipets, volumetric, two, l0-ml,
Weighing scale, reads to at least two decimal places,
White paper.
2. Reagents:
Buffer solution, Hydranal (Riedel de Haen) or Hydra-Point (J.T. Baker), 500 ml,
TITRANT, Hydranal Composite 5 (Riedel de Haen) or Hydra-Point Titrant 5, 1 L,
Methanol, reagent grade, 500 ml.
3. Analytical Procedure:
Charge burette with Hydranal titrant.
Pipette 10 ml of methanol into clean dry Erlenmeyer flask.
Pipette 10 ml of Hydranal buffer into the same flask and gently swirl to mix.
Place white paper below burette. Place the flask under the burette and slowly titrate, with
gently swirling the Hydranal titrant into the flask until a light yellow-brown colour persists
(about 3 ml).
Record titrant reading.
Place the flask on balance and add about 0.5 g of test sample, and record weight.
Gently swirl flask to mix sample.
Place flask under burette and titrate back to the same yellow-brown colour and
record the reading.
Repeat and average % H2O readings.
4. Calculate Water Content as follows:
H2O = [Consumption titrate X titrant value X l00] ÷ sample weight
where:
consumption = second burette reading of hydranal composite 5 titrant minus the first
burette reading, ml.
titrant value = 5 mg/ml H2O, mg/ml, and sample
weight = weight of sample added, mg.
5. Repeat and average % H2O readings
Page 4-48
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
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
Page 4-49
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/PR/UT02
4.4 ULTRASONIC INSPECTION PROCEDURE

4.4.1 Scope
This procedure establishes the AESC minimum requirements for all Ultrasonic
inspections carried out on aircraft structures, components and engines under the
jurisdiction of any aviation authority and may be used as a contractual
requirement for a subcontractor.
1. The following documents form a part of this procedure to the extent specified
herein.
a. NAS 410 to latest revision - Certification and Qualification of
Nondestructive Test Personnel.
Nondestructive Testing.
c. AESC Written Practice No AESC/NDT/MANUAL/002- Training, Qualification
and Certification Nondestructive Test Personnel.
d. ASTM E317 – Evaluating Performance Characteristics of Ultrasonic Pulse-
Echo Testing Systems without the use of Electronic Measurement Instruments
e. BS EN 583-1 UT General Principles
f. BS EN 583-2 Sizing
g. BS EN 12668-3 Equipment Verification
h. BS EN 1330-1 NDT General Terms
i. BS EN 1330-2 NDT Common Terms
j. BS EN 1330-4 Terms used in Ultrasonic Testing
k. Boeing NDT Manuals
GoodRich NDT 32-40-72
l. Airbus N T M
or Aviation Authority references cited herein and aircraft maintenance practices,
the text of OEM, Aviation Authority or aircraft maintenance takes precedence.
4.4.3 Terminology
Page 4-50
4. NDT Code or Specification: a public document controlling standards of

NDT application e.g. EN4179, Aircraft NDT Manuals, ASTM Standards.
6. Scan: to move the probe over the surface of the specimen.

7. Indication: any disturbance of the ultrasonic beam causing a change in the
screen or meter response.
4.4.4 Safety
There are no special safety precautions related to this method. However inspectors
should be aware of standard safety practices within AESC including operations in and
around aircraft, within the hangar and on the apron
4.4.5 Personnel
This procedure is to be performed by qualified and certified NDT inspectors. NDT
inspectors shall meet the requirements detailed within AESC Written Practice as Level
1, 2 or 3 inspectors. Level 1 personnel shall only work with written instructions under
Level 2 supervision and shall not release to service any components.
4.4.6 Identification and Datum Points
No parts, materials, or aircraft shall be inspected unless there is clear
identification such that the part, material or aircraft is traceable. Wherever indications
are recorded there shall be a datum referenced in any records such that the location of
the indication can be clearly identified later.
4.4.7 Surface Preparation
No Ultrasonic inspection shall be undertaken unless the scan surface has been
inspected and found to be smooth and clean, free of debris and dirt.
4.4.8 Extent of Inspection
No ultrasonic inspection shall be carried out unless the scan area and anticipated defect
depth and location is clearly identified.
4.4.9 Equipment Specification
No ultrasonic inspection shall be carried out unless the equipment required to
complete the test is detailed at a level generically such that suitable equipments are
confidently and easily identified.
No ultrasonic inspection shall be carried out unless any AESC standard used to pre-
calibrate the equipment has a certificate of conformity and/or current calibration
certificate as applicable.
4.4.10 Equipment Calibration
All calibration shall be controlled by clear unambiguous instructions that define an
objective and repeatable sensitivity standard that clearly defines defect
indications from other factors that may effect the ultrasonic inspection.
checked for serviceability, battery condition and correct functioning of all probes, coils
and controls. In the event that equipment is found to be unserviceable, it shall be
clearly marked as such and removed from service until it is repaired.
Page 4-51
4.4.11 Equipment Annual Performance Checks (annual calibration)

Equipment shall be performance checked on an annual basis and shall be
marked with a label identifying the due date for next performance check.
4.4.12 Equipment Checks
No ultrasonic equipment may be used for inspection purposes unless it is first
4.4.13 Instruction Details
1. Instructions for Ultrasonic Inspections shall take the form of:
a. Manufacturer nondestructive test manual b.
Airworthiness Directives
c. Service Bulletins
d. AESC Instructions (generic or specific)
2. A Level 1 certified inspector shall not carry out an inspection without
reference to an instruction as defined above. All AESC instructions shall be
approved by Level 3. Level 1 inspectors shall be trained by a Level 2/3 on
instruction compliance, as necessary to ensure competence prior to exercising
independent inspections.
3. AESC NDT Instructions shall be written to be understood by a Level 1
inspector and shall include the elements listed below as a minimum.
a. A unique reference number b.
Purpose of the test
5. Personnel:
The minimum level of certification required to apply the instruction
6. Apparatus to be used:
Equipment to be used together with settings
7. Product/area to be tested:
a. Component identification, brief description and a drawing if appropriate
8. Test conditions:
a. Pre-test preparation of the test area b.
Post test cleaning and of test object
Action to be taken when defect are detected.

Page 4-52

a. Step-by-step instructions in the application of the NDT technique with
reference to sketches if appropriate including pre-calibration and post
calibration checks.
b. A statement instructing the inspector on actions to be taken in the event that
10. Recording and classifying results:
4.4.14 Assessment of Test Results

The instruction must specify the minimum size and type of indication sought and where
applicable, the method of classification and sizing to be employed.
4.4.15 Reporting of Test Results

Reports of inspection results shall be in accordance with AESC MOE. Where requested by
QA, normally on location of a rejected flaw, the Head of NDT may be asked to generate
a detailed report. Such a report shall contain the following information headings as a
minimum and each shall have a detailed narrative with accompanying digital images and
drawings as required.
1. AD, SB, Procedure/Instruction Reference
2. Component part number, serial number, aircraft registration
3. Equipment used with serial number.
4. Equipment settings
5. Defect location, size and description
6. Status of indications, “Rejected”, “Acceptable”, “in limits” etc.
7. Inspector’s name and qualification
8. Inspector’s signature, Head of NDT’s signature
4.4.16 Non-Compliance Statement
Any inspection that cannot be complete for technical reasons beyond the control of the
inspector shall be reported to the Head of NDT for investigation.
4.4.17 Attachments
None
Page 4-53
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/INST/ET02
4.5. EDDY CURRENT INSPECTION INSTRUCTION
4.5.1 SCOPE:
This instruction is developed to cover the eddy current examination of aircraft wheels using the
high frequency eddy current method compliant with ET procedure AESC/NDT/PR/ET02
4.5.2 IDENTIFICATION
Aircraft wheel halves. See figure 1
Material: Aluminum or magnesium Alloys
4.5.3 PURPOSE OF TEST
To detect surface breaking fatigue cracks
4.5.4 EXTENT OF INSPECTION
See detail in applicable CMM
4.5.5 STANDARDS AND REFERENCES:
a) AESC’s written practice for qualification and certification NDT personnel compliant with
EN 4179
b) CMM
c) ET procedure AESC/NDT/PR/ET02
4.5.6 SAFETY:
Before carrying out this instruction, the inspector shall be familiar with the relevant safety
procedures both within AESC and statutory regulations appropriate to the NDT method. There
are no special safety precautions related to this method.
4.5.7 PESONNEL:
This instruction requires the inspector to be currently certified to AESC written practice
compliant with EN 4179, Eddy Current Method, Aerospace materials and components level 1 or
2.
4.5.8 EQUIPMENT SPECIFICATION:
Equipment: DEFECTOMETER 2.837 or impedance plane equipment NORTEC 500S
Probe:
Page 4-54
4.5.8.1 SCOPE:
This instruction is developed to cover the eddy current examination of aircraft wheels using the
high frequency eddy current method compliant with ET procedure AESC/NDT/PR/ET02
4.5.8.2 IDENTIFICATION
Aircraft wheel halves. See figure 1
Material: Aluminum or magnesium Alloys
4.5.8.3 PURPOSE OF TEST
To detect surface breaking fatigue cracks
4.5.8.4 EXTENT OF INSPECTION
4.5.8.5 STANDARDS AND REFERENCES:
a) AESC’s written practice for qualification and certification NDT personnel compliant with EN
4179
b) CMM
c) ET procedure AESC/NDT/PR/ET02
4.5.8.6 SAFETY:
procedures both within AESC and statutory regulations appropriate to the NDT method. There
are no special safety precautions related to this method.
4.5.8.7 PESONNEL:
This instruction requires the inspector to be currently certified to AESC written practice
compliant with EN 4179, Eddy Current Method, Aerospace materials and components level 1 or
2.
4.5.8.8 EQUIPMENT SPECIFICATION:
Equipment: DEFECTOMETER 2.837 or impedance plane equipment NORTEC 500S
Probe:
- Straight-Microtip pencil probe unshielded MMP-40/200K-1M, Max diameter at tip is 3 mm.

See figure 3
- Right angle tip 0.2 in drop shielded pencil probe MP902-45/200-1M,Max diameter at tip is 3
mm. See figure 4
Page 4-55
- Right angle tip 0.03 in drop, shielded pencil probe MP9003-45/200-1M,Max diameter at tip is
3 mm. See figure 5
Calibration block: Aluminum alloy, 35 to 45% IACS with 0.5 mm EDM
See figure 2 on page 4/4
NOTE: Any comparable eddy current equipment may be used provided that it satisfies
the requirements of this instruction and is capable of resolving the reference slot in the
calibration standard at the required level of resolution.
4.5.8.9 EQUIPMENT CHECKS:
In according with equipment manufacturer’s operating instruction
4.5.8.10 INITIAL SET UP PROCEDURE:
In according with equipment manufacturer’s operating instruction
4.5.8.11 EQUIPMENT CALIBRATION
a. Impedance plane equipment
- Set HP filter to off. Set LP filter to 100 Hz
- Set Null point to 10V and 80H
- Set H gain to 9dB less than V gain
- Set frequency to 300 KHz
- Null probe on calibration block and set lift-off horizontal.
- Use Gain control to obtain 9 main-scale divisions vertical rise from the 0.5 mm EDM slot
in the calibration block. Set the audio/visual alarm to trigger at 5 main-scale divisions.
b. Crack detector
- Use the calibration Standard from the relevant material to calibrate the instrument for
lift off and zero in accordance with the manufacturer's instructions.
- Position the probe directly over the 0.5 mm slot in the calibration standard and adjust
the instrument sensitivity so that the meter needle is at 80 % full scale.
Page 4-56
4.5.1.1 SURFACE PREPARATION
Ensure surfaces to be inspected free from dirt and grease. Carry out visual inspection this area to
detect surface discontinuities which may affect the inspection process. To ensure a satisfactory
scan pitch is maintained a coating of dye penetration developer can be sprayed on to the scan
area. During inspection the scan pitch will be traced in this coating allowing it to be monitored.
4.5.1.2 INSPECTION PROCESS
a. Bead seat area
- Move a unshielded pencil probe in circumferential or sinusoidal scans as illustrated in

figures below:
Circumferential scans
Sinusoidal scans
Page 4-57
b. Peripheries of bolt holes:
Using a shielded pencil, type probe inspect the Peripheries of bolt holes on both sides of half
hub. Distance of scan from bolt holes should be 1 mm.
c. Radii in nut and bolt head seats, web radii, inner wall radii in centre flange
Using a shielded pencil, Right angle tip 0.2 in drop type probe to inspect
d. Peripheries of ventilation/lightning holes:
Using a shielded pencil, Right angle tip 0.2 in drop type probe to inspect. The distance of scan
from edge of hole should be 2 mm
e. Radii under drive block abutments,
Using a shielded pencil, Right angle tip 0.2 in drop type probe to inspect Radii under drive block
abutments using a sinusoidal scan pattern. The pitch of scan should be 2 mm with amplitude of
5 mm. Scan should extend 5 mm beyond the edges of drive block abutment.
f. ‘O’ ring seal groove, lock ring groove, tie bolt holes
Using a shielded pencil, Right angle tip 0.03 in drop type probe to inspect ‘O’ ring seal groove,
lock ring groove using sinusoidal and circumferential scans with pitch 2 mm and 1 mm.
4.5.8.14 ASSESSMENT OF TEST RESULTS
- Investigate any signal that trigger the audio/visual alarm
- For impedance plane equipment: all vertical indications greater than 5 main-scale vertical
movement not attributable to edge effect, geometry, ferrous effect or probe handling are to
be considered as fatigue cracks.
- For crack detector: Cracks will be indicated by a sharp meter needle deflection to the right >
40% of full scale.
- Measure the length of all detected cracks
4.5.8.15 FINAL NDT REQUIREMENTS
None
4.5.816 REPORTING OF TEST RESULTS
If crack indications found, fill in NDT report form and send it to QA in according with Defect
report procedure.
Page 4-58
4.5.8.17 NON-COMPLIANCE STATEMENT
If the operator unable to comply with the procedural requirements, the NDT inspection
suspended and the level 3 advised.
4.5.8.18 ATTACHMENTS
- Figure 1: wheel halves

- Figure 2: Calibration standard
- Figure 3: Straight-Microtip pencil probe unshielded
- Figure 4: Right angle tip 0.2 in drop shielded pencil probe
- Figure 5: Right angle tip 0.03 in drop, shielded pencil probe
- Figure 1: Wheel halves
Page 4-59
- Figure 2: Calibration standard
- Figure 3: Straight-Microtip pencil probe unshielded
- Figure 4: Right angle tip 0.2 in drop shielded pencil probe
- Figure 5: Right angle tip 0.03 in drop, shielded pencil probe
Page 4-60
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/INST/MT02
4.6 MAGNETIC PARTICLE INSPECTION INSTRUCTION
4.6.1 SCOPE
This instruction is documented as the process by which the aircraft wheel parts like tie bolts,
drive keys and so on are to be inspected using head shot and coil, fluorescent, wet continuous
magnetic particle method. This instruction compliant with AESC/NDT/PR/MT02.
Tie bolts or drive keys P/N
Material: ferromagnetic
Reference Datum: as required - see applicable CMM
4.6.3 PURPOSE OF TEST
To detect near or on surface breaking fatigue cracks
4.6.5 STANDARDS AND REFERENCES
a) AESC’s written practice for qualification and certification NDT personnel compliant with
EN 4179
d) CMM
e) MT procedure AESC/NDT/PR/MT02
f) Process Materials Safety Data Sheets
4.6.6 SAFETY
procedures both within AESC and statutory regulations appropriate to the Magnetic particle
testing method. Do not touch parts energized with electrical current. Do not use this equipment
in areas with water on the floor. Wear rubber gloves rated for electrical work and rubber-soled
shoes or boots because electrocution is possible. Tester using black light sources should avoid
looking directly at the sources, all aerosols shall be used in well ventilated areas, otherwise face
dust filter mask must be worn.
Page 4-61
4.6.7 PESONNEL
This instruction requires the inspector to be currently certified and authorised to AESC written
practice compliant with EN 4179, Magnetic particle testing Method, Aerospace materials and
components level 1 or 2.
4.6.8 EQUIPMENT SPECIFICATION
Instruments and materials
a. Wet horizontal equipment PPA-423. AC output 3000A, 10" diameter coil, DeMag AC output
3000A.
b. Blacklight ZB-100 at 365 nm wavelength
- UV light meter: UV 340 from General Tools
- White light meter: from Extech
- Gaussmeter: Model 410 from LakeShore
- Magnetic Particles, Fluorescent, Wet Method, Oil Vehicle, Aerosol Packaged 14 AM from
Magnaflux
4.6.9 EQUIPMENT CHECKS
a. Ensure equipment pre-use checks have been carried out
b. Ensure UV-A light intensity is greater than 1000 W/cm2 at 15in. (using ASTM 1444-05)
c. Ensure white light intensity is less than 20 lux at the inspection surface
4.6.10 EQUIPMENT CALIBRATION
a. Verify bench unit ammeter calibration
b. Verify UV-A and white light meters calibration
c. Verify Gaussmeter calibration
4.6.11 SURFACE PREPARATION
Ensure surface is clean. Carry out visual inspection to detect surface discontinuities which may
affect the inspection process.
4.6.12 INSPECTION PROCESS
Inspect component i.a.w table below
Page 4-62
a. Inspect under UV-A illumination assisted by x 10 magnification
b. Ensure UV-A light intensity is greater than 1000 W/cm2 at the inspection surface.
d. Using ASTM 1444-05 only, ensure tangential field strength is a minimum of 30 Gauss
e. Carry out demagnetisation. Ensure residual field is less than 3 gauss
Description of
shot component amperage defect sought
test
12-32A/mm Longitudinal and

1 tie bolts, drive keys head shot circular
diameter radial on end face
NI= Transverse all

2 tie bolts, drive keys Coil longitudinal
45000/(L/D) surface
4.6.13 ASSESSMENT OF TEST RESULTS
Assess all indications observed. Linear discontinuity indications are to be considered as cracks.
4.6.14 EXAMINATION STANDARD
See applicable CMM for accept - reject criteria
Reports are to be i.a.w company procedures using attached diagram for defect plots. Report is
to include:
- Defect type, position and size

- Magnetic bench serial number
- UV-A lamp serial numbers and light intensities
- Tangential field strength obtained
4.6.16 POST TEST INSTRUCTIONS
Remove all traces of indications and marks from the specimen surface. Ensure demagnetized
and clean.
4.6.17 NON-COMPLIANCE STATEMENT

Page 4-63
4.6.18 ATTACHMENTS
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/INST/PT02

Page 4-64
4.7 PENETRANT TESTING INSTRUCTIONS

4.7.1 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-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 lint-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)
Page 4-65
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.
4.7.2 SOLVENT REMOVABLE 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 C, Form d

Approved for Aircraft parts inspection
Reference
ASTM E1417
Materials
Pre-cleaner ARDROX 20% or approved non residue oil free cleaner
Penetrant: 970P25E Sensitivity Level 3 or its equivalent
Remover: 9PR5 its equivalent
Developer: 9D4A or its equivalent
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. PREPARATION
Prepare inspection area to reduce ambient white lighting or inspect in darkened area.
3. PRE-CLEAN
Wipe with solvent-dampened lint-free cloth, followed by a clean lint-free cloth.
Page 4-66
4. PENETRANT APPLICATION
Apply Penetrant using a clean swab or brush to the inspection area only. Do not an aerosol spray
to spray on the penetrant unless the component requires 100% inspection and is removed from
the aircraft.. Contact time 10 min. minimum. If penetrant dries, re-process from step 2.
5. EXCESS PENETRANT REMOVAL:

Remove excess penetrant under black light by wiping with a dry nap-free cloth, towel or tissue,
turning frequently, followed by a remover moistened dry nap-free cloth until all traces of
penetrant are removed. Dry area with clean dry-nap free cloth, towel or tissue.
6. DEVELOPER APPLICATION
Apply developer to give a thin uniform film, just sufficient to obscure the specimen surface.
Minimum contact time shall be 10 minutes.
7. INSPECTION
10 minutes has elapsed. Inspection is to be assisted by X 3 to X10 magnification.
8. ILLUMINATION
UV-A light intensity is to be greater than 1500 µW/cm², at the inspection surface.
White light intensity is to be less than 20 lux at inspection surface. For inspections carried out
on wing, or in hangar conditions, the local area should be darkened by the use of screens
etc., or alternatively the inspection should be carried out after dark with hangar lights
extinguished.
9. EVALUATION
a) relevant
b) non-relevant
c) spurious (false)
Evaluation shall be accomplished by wiping each indication with a single wipe using a volatile
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. Measurements
shall be accomplished by use of an optical graticule.
10. POST-EXAMINATION CLEANING Remove all traces of penetrant and developer using
approved solvent cleaner.
11. PROTECTION
Reapply surface protection as required
Page 4-67
4.7.3 WATER WASHABLE 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 A, Form d

Approved for aircraft parts inspection
Reference
ASTM E1417
Materials
Pre-cleaner ARDROX 20% or its equivalent
Penetrant: 970P25E Sensitivity Level 3 or its equivalent
Developer: 9D4A or its equivalent
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. EXCESS PENETRANT REMOVAL:

Remove excess Penetrant by water spray wash, monitored under UV-A lamp at 1000
µW/cm² minimum with a maximum of 10fc (107.6 lx) of ambient visible light at the part
surface. Extreme care should be taken to avoid overwashing.
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°
Page 4-68
5. DRYING
Dry in hot air oven, oven temperature 70°C / 158°F, until dry (preferable temperature is 50°C
/ 122°F)
6. DEVELOPER APPLICATION
Apply Non-aqueous developer. Minimum contact time shall be 10 minutes, maximum 30
minutes.
7. INSPECTION
10 minutes has elapsed. Inspection is to be assisted by X5 to X10 magnification.
8. EVALUATION
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.
9. 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
10. POST-EXAMINATION CLEANING

Immediately protect from corrosion by wrapping or covering with protective paper. Forward for
process cleaning
11. PROTECTION
Reapply surface protection as required
Page 4-69
4.7.4 PENETRANT INSPECTION INSTRUCTION FOR WHEEL
4.7.4.1 SCOPE:
This instruction is documented as the process by which the aircraft wheel parts are to be
inspected using the fluorescent penetrant method to ASTM 1417-05 Type I, method A form d.
4.7.4.2 IDENTIFICATION
Aircraft wheel parts
Material: aluminum or magnesium alloys
4.7.4.2.1 PURPOSE OF TEST:
To detect near or on surface breaking fatigue cracks
4.7.4.2 EXTENT OF INSPECTION
4.7.4.3 STANDARDS AND REFERENCES
a. AESC’s written practice for qualification and certification NDT personnel compliant with
EN 4179
b. CMM
c. ASTM E1417-05: Standard practice for Liquid penetrant testing
d. Process Materials Safety Data Sheets
4.7.4.4 SAFETY:
procedures both within AESC and statutory regulations appropriate to the Liquid penetrant
testing method.
4.7.4.5 PESONNEL:
This instruction requires the inspector to be currently certified and authorised to AESC written
practice compliant with EN 4179, Magnetic particle testing Method, Aerospace materials and
4.7.4.6 EQUIPMENT SPECIFICATION:
Page 4-70
a. AESC penetrant inspection Line N0.1 and associated safety equipment.
b. Air circulating drying oven. Temperature:
c. Water wash station. Water temperature: 10-350C; pressure 15-35 psi; UV-A (Blacklight)
source minimum intensity 300 W/cm2.
d. UV-A (Blacklight) source producing UV-A light at 365 nm wavelength, minimum intensity,
1000 W/cm2.
e. UV-A light meter
g. White light meter
h. x 10 hand magnifier
j. Penetrant ZL-60C from Magnaflux
k. Developer: ZP-9F from Magnaflux
4.7.4.7 EQUIPMENT CHECKS:
b. Ensure UV-A light intensity is greater than 1000 W/cm2 at 15in. (using ASTM 1417-05)
4.7.4.8 EQUIPMENT CALIBRATION:
- Verify bench unit ammeter calibration
- Verify UV-A and white light meters calibration
4.7.4.9 SURFACE PREPARATION:
Ensure surface is clean. Carry out visual inspection to detect surface discontinuities which may
affect the inspection process. All cleaning steps are done in wheel section before transfer to
NDT section. If a clean, white cloth shows dirt after it is wiped on the part, send back to clean
the part again.
4.7.4.10 INSPECTION PROCESS
Three first steps are done in wheel section
a. Remove paint (at overhaul), clean parts in cleaning equipment.
b. Rinse under water spray to remove cleaning solution
Page 4-71
c. Place component in drying oven until completely dry. Allow surface

temperature to cool to 500C.
d. Immerse in penetrant for 1 minute and drain for 19 minute. Contact time 20
minutes.
e. Remove excess penetrant by water spray. Min spray distance 300 mm. Water
temperature 10-350C
f. Confirm penetrant removal under UV-A light - minimum intensity 300 W/cm2 at the
inspection surface.
g. Place component in drying oven until completely dry. Surface temperature not to
exceed 500C.
h. Apply non-aqueous developer. Minimum contact time 10 minutes
j. Inspect under UV-A illumination, assisted by x 10 magnification, immediately after

application of developer and also after the 10 minutes contact time
Ensure UV-A light intensity is greater than 1000 W/cm2 at the inspection surface.
Ensure white light intensity is less than 20 lux at the inspection surface
4.7.4.11 ASSESSMENT OF TEST RESULTS
Assess all indications observed. Linear discontinuity indications that have a length more than
three times the width are to be considered as cracks. Indications may be evaluated by wiping
the indication with a solvent-dampened swab or brush, allowing the area to dry, and
redeveloping. Redevelopment time shall be at least ten minutes, except nonaqueous
redevelopment shall be three minutes minimum. If no indication reappears, the original
indication is considered false. This procedure may be performed twice for any given original
indication.
4.7.4.12 EXAMINATION STANDARD
4.7.4.13 REPORTING OF TEST RESULTS
Reports are to be i.a.w company procedures using attachted diagram for defect plots. Report
is to include:
- Defect type, position and size

- Penetrant system used and chemical batch number
- UV-A lamp serial numbers and light intensities
- Control times
Page 4-72
4.7.4.14 POST TEST INSTRUCTIONS
Remove all traces of indications and marks from the specimen surface. Ensure clean. All
defective specimen are to be identified and quarantined i.a.w. company procedures.
4.7.4.15 NON-COMPLIANCE STATEMENT
suspended and the level 3 advised
4.7.4.16 ATTACHMENTS
- Figure 1: Identification of Areas on Wheel Halves or Wheel Bases
Figure 1: Identification of Areas on Wheel Halves or Wheel Bases
Page 4-73
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/INST/UT02
4.8 ULTRASONIC INSPECTION INSTRUCTION
4.8.1 SCOPE:
This instruction is documented as the process by which the aircraft wheel tie bolts and so on
are to be inspected using ultrasonic method. This instruction compliant with
AESC/NDT/PR/UT02
Tie bolts P/N
Material: Steel or inconel
Note: Steel bolt can also be inspected for cracks by magnetic particle inspection.
4.8.3 PURPOSE OF TEST:
a. Use this procedure to do an inspection for broken or badly cracked bolts.
b. See Figure 1 to identify the type of bolts that can be examined with this inspection.
4.8.5 STANDARDS AND REFERENCES
g) AESC’s written practice for qualification and certification NDT personnel compliant with
EN 4179
h) CMM
i) UT procedure AESC/NDT/PR/UT02
j) Boeing NTM
k) Goodrich NDT manual
4.8.6 SAFETY
procedures both within AESC and statutory regulations appropriate to the Ultrasonic testing
method.
4.8.7 PESONNEL
This instruction requires the inspector to be currently certified and authorized to AESC written
practice compliant with EN 4179, Ultrasonic testing Method, Aerospace materials and
Page 4-74
PART 4 – NDT SPECIFIC PROCEDURES & WRITTEN INSTRUCTIONS – AESC/NDT/INS/UT02
4.8.8 EQUIPMENT SPECIFICATION
a. General
- Use inspection equipment that can be calibrated on the reference standard as

specified in Paragraph X.
b. Instrument
- The pulse-echo instrument specified below, was used to prepare this procedure.
+ USN 60; Krautkramer-Branson
c. Transducer
- Use a transducer that:
+ Operates between 5 and 10 MHz.
+ Has a 0.25 inch diameter.
d. Reference Standards
- Calibration Bolt – Use a bolt of equivalent material, type and length as the bolt to be
examined.
- Bolt properties are specified on the applicable engineering drawings.
- Calibration Block - Use a 1 inch thick piece of material that is equivalent to the
material in the bolt to be examined.
e. Couplant
- Use a couplant that not harm the test material.
4.8.9 EQUIPMENT CHECKS:
4.8.10 SURFACE PREPARATION:
a. Clean the end of the inspection bolt that touches the transducer.
4.8.11 EQUIPMENT CALIBRATION:
a. Apply couplant to the calibration block and the ends of the calibration bolts.
Page 4-75
b. Make the initial instrument adjustments. Refer to the operating manual.
- Make sure that the instrument reject and signal suppression are off during the
calibration and the inspection.
c. Put the transducer on the calibration block.
d. Adjust the display with the range controls so one major division on the display is
equivalent to 1 inch of the calibration block length.
e. Adjust the instrument gain with the calibration bolt for one of the conditions that
follow:
- If you do the inspection on the bolt head (annulus):
+ Put the transducer tightly on the flat surface of the calibration bolt head (annulus).
+ Adjust the gain to get a back surface signal of 40 percent of the display height
(Figure 2).
- If you do the inspection on the threaded end of the bolt:
+ Put the transducer tightly on the flat surface of the threaded end of the calibration
bolt.
+ Adjust the gain to get a back surface signal of 60 percent of the display height
(Figure 3).
4.8.12 INSPECTION PROCESS
a. Identify the material properties of the bolt to be examined. Refer to the applicable
engineering drawings.
b. Identify which end of the bolt must be used to do the inspection.
c. Apply couplant to the inspection end of the bolt.
d. Put the transducer tightly on the flat part of the inspection end of the bolt and make a
scan.
e. Monitor the display for a signal equivalent to the one you got during calibration.
NOTE: The transducer used for the inspection must not cause noise signals between the initial
signal and the back surface signal that are more than 10 percent of the display height.
Page 4-76
f Compare the bolt length as shown on the display to the known length of the calibration
bolt or block to identify the bolt length;
g. If the bolt is 0.25 inch shorter or 0.5 inch longer than the calibration bolt, then refer to
the engineering drawing to make sure of the length.
4.8.13 ASSESSMENT OF TEST RESULTS
a. A break along the shank of the bolt can be identified by a signal from the break and a
missing back surface signal (Figure 4, Figure 5) .
b. A large crack without shank separation can be identified by a crack signal of more than
20 percent of the display height and a back surface signal (Figure 6, Figure 7).
c. If the bolt is broken irregularly, the reflected ultrasound can be turned away from the
transducer. A decrease in the back surface signal can be an indication of a cracked or
broken bolt.
d. Compare all results to the signals you got during calibration.
4.8.14 EXAMINATION STANDARD
If crack indications found, fill in NDT report and send it to QA in according with Defect report
procedure.
4.8.16 POST TEST INSTRUCTIONS
Remove all traces of indications and marks from the specimen surface.
4.8.17 NON-COMPLIANCE STATEMENT
4.8.18 ATTACHMENTS
- Figure 1: Typical Bolt types
- Figure 2: Signals from bolt head inspections
- Figure 3: Signals From Inspections at the Threaded End of a Bolt
- Figure 4: A break near the sound entry point
Page 4-77
- Figure 5: A Break Away from the Sound Entry Point
- Figure 6: A Crack Near the Sound Entry Point
- Figure 7: A Crack Away from the Sound Entry Point
Page 4-78
Page 4-79
Page 4-80
Page 4-81
Page 4-82
Page 4-83
Page 4-84
Page 4-85

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Ha Noi Main Facility (MT1) Ho Chi Minh Branch (MT2)

Tel: (84)-4-38185930 InternationalAirport, HCM City.

Fax: (84)-4-38185931 Tel: (84)-8-6 6751341

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1.1 TABLE OF CONTENTS

1.2 RECORD OF REVISIONS

Revision No Revision Date Revision Reason Remark

00 Nov,2008 Original Issuance

01 Jun,2010 Revised and additional

1.3 SUMMARY OF AMENDMENT

Part Removed Pages Inserted Pages Reason For Amendment

This page is updated whenever there is any amendment.

The NDT Manual is approved by the NDT Level3.

This table of abbreviation will be updated if any abbreviation used.

1.6 LIST OF EFFECTIVE PAGES

3-39 002 02 Apr 2012 4-21 002 02 Apr 2012

3-40 002 02 Apr 2012 4-22 002 02 Apr 2012

3-41 002 02 Apr 2012 4-23 002 02 Apr 2012

3-42 002 02 Apr 2012 4-24 002 02 Apr 2012

3-43 002 02 Apr 2012 4-25 002 02 Apr 2012

4-1 002 02 Apr 2012 4-26 002 02 Apr 2012

4-2 002 02 Apr 2012 4-27 002 02 Apr 2012

4-3 002 02 Apr 2012 4-28 002 02 Apr 2012

4-4 002 02 Apr 2012 4-29 002 02 Apr 2012

4-5 002 02 Apr 2012 4-30 002 02 Apr 2012

4-6 002 02 Apr 2012 4-31 002 02 Apr 2012

4-7 002 02 Apr 2012 4-32 002 02 Apr 2012

4-8 002 02 Apr 2012 4-33 002 02 Apr 2012

4-52 Apr 2012 4-77 002 02 Apr 2012

4-68 002 02 Apr 2012

4-69 002 02 Apr 2012

4-70 002 Apr 2012

Truong Thanh Chung Mai The Chien

1.7 REVISION PROCEDURE

3. Review and submit for approval:

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012 Page 2-1

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012 Page 2-2

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2.3 NDT FACILITIES

AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012 Page 2-3

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2.3.1.2 NDT Equipment

AESC/NDT/MANUAL/002, REV.02, DATED. APR-2012 Page 2-4

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2.3.1.3 NDT FACILITIES

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2.3.2 NDT Equipment

2.4 PRIVILEGES OF NDT STAFF

1. Process parts, document results and perform equipment standardization in

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2. External supplier technical NDT audits, surveys or assessments.

PART2- MANAGEMENT, FACILITIES & PERSONNEL QUALIFICATION

2.5 EQUIVALENT ASSESSMENT OF NDT EQUIPMENT AND MANUFACTURE

PART 3- WRITTEN PRACTICE – AESC/NDT/WP02

PART 3- WRITTEN PRACTICE – AESC/NDT/WP02

PART 3- WRITTEN PRACTICE – AESC/NDT/WP02

3.2 NORMATIVE REFERENCES

3.2.2 Order of Precedence

PART 3- WRITTEN PRACTICE – AESC/NDT/WP02

PART 3- WRITTEN PRACTICE – AESC/NDT/WP02