Appendix A- FPI Line Calibration Requirements.pdf

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

60-00-00

NDT 8DAP

Mar 31/23

GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

(1) Castings are unlikely to be totally free of indications and the following shall be applied in determining the acceptability of the parts in which any indications are found.

(2) No cracks, cold shuts, inclusions, segregation, through or linear indications are allowed.

(3) Isolated fine rounded porosity is acceptable.

(4) Other rounded indications up to 0,4 mm diameter are acceptable if the void cannot be seen at x 10 magnification under Visible light conditions per section 5.B.(2)(g)3.

(5) Voids up to 0,4 mm that can be seen at x 10 magnification under Visible light are acceptable providing that the void is separated from an adjacent void by a distance of at least 8 times the diameter and there are no more than 15 indications in an any 25 mm x 25 mm area. Indications which exceed these limits should be referred to a DP Level 3 technician for a decision as to their possible acceptance.

F. Any questionable indications shall be referred to a DP Level 3 technician.

G. Where defects may be removable within actual or possible limits, the re-work procedure shall be applied

H. All re-work shall be documented.

I. Defects which will not be removable within drawing or concession limits are cause for immediate rejection.

8. Re-Work Procedure

A. For parts that have been re-worked to remove Penetrant indications, process in accordance with

PS5141.

9. Documentation & Records

A. Unless otherwise stated, parts which have been accepted using Penetrant inspection shall have all relevant paperwork ink stamped.

B. Records of all parts processed through Penetrant inspection shall be kept in accordance with document retention procedures. These records shall be made available to authorised customer representatives and regulatory authorities when requested.

C. All control checks, performance tests and calibrations shall be recorded on an appropriate control sheet and retained in accordance with QMP25.

10. Process Control Requirements

A. A calibration system shall be established in accordance with ISO 10012-1, or equivalent, for the calibration and certification of all gauges, meters, measurement, and control equipment.

B. Equipment and materials shall be tested at intervals stated in Table 1 or whenever modifications, adjustments or repairs are made.

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GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

C. If any of the facilities, equipment or materials fails to meet the requirements of this specification, further inspection shall be suspended until appropriate corrective actions, which address those failures, have been conducted.

D. It shall also be determined if parts inspected prior to the test failure should be re-inspected.

E. System Performance Test

(1) Perform daily performance checks using a known defect standard (PSM 5 TAM Panel or similar).

Process the known defect standard through the system using production processing parameters and compare the results to those obtained with reference (new) samples of the same materials.

(2) Compare the known defect standard to a colour photograph (1:1 reproduction) of the same standard processed with reference materials.

(3) Known defect test panels shall be capable of demonstrating unacceptable system performance.

(4) Maintenance procedures for re-usable test panels shall ensure:

(a) Cleaning between uses removes penetrant from defects.

(b) That cleaning will not physically change the standard.

(c) Detection of any physical changes in the test panel, which would render the test panel unusable.

(5) Review the condition of the known defect standard(s) for deterioration annually. Such review shall be capable of identifying changes in the discontinuity length or width, in excess of 30% of the baseline measurement. Results shall be documented. Review may consist of:

(a) Measurement of the discontinuity.

(b) Comparison with a photo of the original discontinuities.

(c) Side by side comparison with a master standard.

(d) Re-certification by the standards manufacturer.

(e) Known defect test panels, which have deteriorated by more than 30% of the original baseline measurements, shall be replaced.

F. Penetrant

(1) Contamination – 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. This shall be performed daily.

(2) Brightness – Conduct brightness tests as specified in ASTM E 1135. Brightness values outside the range of 90-110% of the standard are unsatisfactory. This shall be performed 6 monthly and results recorded.

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Mar 31/23

GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

(3) Water Content (Method A and A(W)only) – Use either ASTM D 95, Karl Fischer or EN ISO 9029 test methods. Maximum water content shall be no greater than 5% by volume. Any failure of this, the material shall be replaced. This shall be checked at intervals shown in Table 1 and results recorded.

NOTE: If spray to waste systems are in use, then the checks detailed in Section 10.F.(1), (2), & (3) are not required.

(6) Penetrant materials that have exceeded their initial shelf life date are permissible to use provided the requirement of paragraph 10 E - H produce acceptable results. Ready-to-use materials as identified in paragraph 5.A.(8) need only meet the requirements of paragraph 10.E.

G. Emulsifiers/Removers

(1) Concentration – Check concentration of the emulsifier/remover with a certified refractometer. The refractometer values obtained shall be compared to actual values obtained from known concentrations of emulsifier. This shall be performed weekly and results recorded.

(2) Variations in concentration shall not exceed +/- 3% of those used in qualifying the system and shall not exceed those as stated in the references SAE AMS 2644 and QPL SAE AMS 2644.

(3) For spray applications the concentration shall not exceed 5%. This will be checked weekly and results recorded.

(4) Replenish or replace emulsifiers/removers as necessary to:

(a) Prevent excessive contamination with penetrant or dirt.

(b) Avoid any signs of separation or cloudiness.

H. Developers

(1) Re-cycled or re-used dry developer shall be checked as specified to check for fluorescence and to ensure it is fluffy and not caked.

(2) Caked dry developer is unsatisfactory and shall be replaced. This shall be checked daily and results recorded.

(3) To check for fluorescence, apply a thin layer of in-use developer to a 4 inch (10cm) diameter flat test panel, using the same method of application used for production parts, and observe under UV- A irradiation. Dry developer exhibiting 10 or more fluorescent specs in the 4 inch (10cm) diameter circle is unsatisfactory and shall be replaced. This shall be checked daily and results recorded.

NOTE: If spray to waste system is in use, then the checks detailed in Section are not required.

I. Area equipment checks

(1) Water pressure gauges, Air pressure gauges and temperature gauges shall be checked each shift to ensure gauges are in working order and operating within the required range.

(2) Compressed air shall be checked each shift to ensure cleanliness and freedom from oil, water or other contaminants.

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GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

(3) Ambient shop temperatures shall be checked each shift to be within the range of 10 to 52°C (50 to 125°F).

(4) The drying oven temperature displayed shall be checked each shift to ensure the maximum temperature is not exceeded.

(5) The viewing area(s) shall be checked each shift to ensure they are free from excess clutter and fluorescent contamination.

NOTE: These checks shall be recorded; however actual values need not be recorded.

J. Gauges

(1) Pressure gauges water and air – Shall be calibrated and certified for the operation range to be used. These shall be calibrated at annual intervals.

(2) Temperature gauges – Shall be calibrated and certified for the operation range to be used. These shall be calibrated at annual intervals.

K. Timers

(1) Timers shall be calibrated at 12 Monthly intervals.

L. Drying Oven

(1) The temperature shall be controlled with a calibrated device capable of maintaining the oven temperature at +/- 8.3° C (15° F) of the temperature for which it is set. This shall be calibrated 6 monthly.

(2) The temperature indicator shall be accurate to +/- 5.6° C (10° F) of the actual oven temperature.

This shall be calibrated 6 monthly.

(3) The oven temperature shall not exceed 71° C (160° F).

M. Lighting and Light Meters

(1) Inspection UV-A lamp intensity to Section 5.B.(2)(g)1, shall be checked daily and results recorded.

(2) Special Inspection UV-A lamp intensity to Section 5.B.(2)(g)3, shall be checked daily or before use and results recorded.

(3) Inspection UV-A lamps shall be checked for cleanliness and integrity and shall be cleaned repaired or replaced as appropriate. This shall be checked daily and recorded.

(4) Visible light intensity to Section 5.B.(2)(g)3, shall be checked weekly and results recorded.

(5) Ambient Visible light levels of 21.5 lux (2 fc) maximum in Inspection area(s). This shall be checked daily and results recorded.

(6) Background UV-A and Visible light levels at the wash stations shall be checked in accordance with Section 6.E.(1)(e). This shall be checked daily and results recorded.

1038936847C Highlight

1038936847C Highlight

1038936847C Highlight

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Mar 31/23

GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

(7) Light Meters (both UV-A Radiometers and Visible light Photometers)

(a) Light meters shall be digital readout.

(b) Light meters shall be calibrated at 6 monthly intervals.

(c) Light meters shall be calibrated at 3 positions minimum, to ensure linearity.

(d) Light meters shall be accurate to within +/- 5%.

(e) UV-A Radiometers shall have a spectral response in the range of 320-400 nm.

N. Etch Control

(1) Etch solutions shall be in accordance with Section 6.C.(2).

(2) Maintained Etch Solutions shall be analysed monthly.

(3) Before use, test pieces shall be processed to ensure removal of 0.0002” (0.005 mm) per surface.

(4) Test piece material shall be 7075-T73 and L77 (or L168).

(5) For propeller blade forgings, test piece material shall be MAT 5205, MAT 5201 or DTD 150.

(6) Visible light levels of 2000 lux (200 fc) shall be available for viewing.

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GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION

Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.

Table 1 Testing/Calibration Intervals

Test Interval Reference

Dryer Temperature Each Shift 10.I

Rinse Water Temperature Each Shift 10.I

Ambient Shop Temperature Each Shift 10.I

Inspection Area Cleanliness Each Shift 10.I

System Performance Daily 10.E

Penetrant Contamination Daily 10.F

Dry Developer Condition Daily 10.H

UV-A Lamp Intensity Daily or Before / after Use (Battery)

10.M

Special UV-A Lamp Intensity Daily or Before / after Use (Battery)

10.M

UV-A Lamp Integrity Daily 10.M

Ambient Visible Light (Insp) Daily 10.M

Wash Station UV-A & Visible Light Daily 10.M

Emulsifier Concentration Weekly 10.G

Visible Light Intensity Weekly 10.M

Penetrant Water Content Method A / A(W) Monthly / Weekly 10.F

Penetrant Brightness 6 Monthly 10.F

Drying Oven Calibration 6 Monthly 10.L

Temperature & Pressure Gauges Annually 10.J

UV-A Radiometer & Visible Light Photometer

6 Monthly 10.M

Timers Annually 10.K

Known Defect Panel Deterioration check Annually 10.E