STS for NDI and Composite Materials Maintenance

Presented to: 2015 A4A NDT Forum

By: Rusty Jones, AFS-300

Date: September 2015

Federal AviationAdministrationFAA Update

2015 A4A NDT Forum

2Federal AviationAdministration

2015 A4A NDT Forum September 2015

Why are we here?

• Information Sharing;– Provide information and updates for NDI

• New guidance, i.e. – NDI facilities, – NDI training and qualification– NDI Job Aid

–I learn from you!!• What are you experiencing in the field?• What do you see as additional guidance needs?• I value your input!!!!



• AFS-300, Steven Douglas, Retired – Timothy Shaver acting

• AFS-301A, Ken Kerzner, Retired– Rolandos C. Lazaris

• AFS-301B, Carol Marteneau, retired– Anthony Janko

• Rusty Jones– Flight Standards to Aircraft Certification

Personnel Changes



• Qualified inspectors,• Differences between composites and metals• Training curriculum needs• Experience needs• Industry Standards• ASI knowledge of NDI• ACO Engineer NDI

FAA Concerns:



• AVS Composite Team– Seven Year Look Ahead– Blessed by AVS-1– Composite projects such as:

• Continued Operational Safety• Certification Efficiency • Workforce Education

• AVS Additive Manufacturing Team– Commonly referred too as 3-D Printing– Road map for guidance & regulations

FAA Initiatives



• AC 65-31B: Training, Qualification, and Certification of Nondestructive Inspection Personnel

• AC 25-29: Development of a Nondestructive Inspection Program/Organization

• FAA Order 8900.1: Inspect a Nondestructive Inspection Program/Facility

• Nondestructive Inspection for Aviation Safety Inspectors Online Job Aid,

New/Revised Guidance



• Definitions: revised definitions of;– a. Certification– b. Certification Based On Previous Experience– c. Practical Examination– d. Qualification Certificate

• Added a sentence to state that AIA-NAS-410 and prEN 4179 are harmonized documents.

• Removed reference to Appendix A which was course outlines for curriculums.

• Added Thermography as a method. Removed reference to visual so as not to imply that certification/qualification is required for visual inspection.

AC-65-31B



• Qualifications:– Added a Note to clarify that there is not a need to differentiate

between metals and composites but that curriculums should be adjusted accordingly.

– Clarified “grandfathering” based on previous experience and documentation required.

– Clarification to “Level I Special qualification.(may need additional clarification)

– Revised Table 1 to include Thermography and reference to additional methods.

– Clarification of qualification based on previous experience• Examination:

– Clarified color perception requirements. – Clarified Practical Examination requirements– Clarified FAA certification

AC-65-31B



• Five General Elements of an NDI Organization– Documentation.– Organization – Environment – Calibration – Training

• Recommendations Pertaining to the Six Most Common NDI Methods.

• NDI Organization Policy and Procedures

AC 25-29:Development of a Nondestructive Inspection Program/Organization



• This section provides guidance for inspecting a nondestructive inspection (NDI) program and/or facility. This section also provides a link to an online job aid that can assist you, an aviation safety inspector (ASI), in performing a standardized approach for surveillance.

FAA Order 8900.1: Inspect a Nondestructive Inspection Program/Facility



• The Aircraft Maintenance Division (AFS-300),designed this job aid to provide a standardized approach to evaluate an NDI organization

• We provide this job aid as a tool . . . ASI’s shouldn’t use this job aid as a pass/fail checklist form during onsite visits.

• Part I includes a general section to record pertinent information about the facility.

• Part II includes specific questions for the six most commonly used methods:

Nondestructive Inspection for Aviation Safety Inspectors Online Job Aid



• Human nature desires to adopt benefits and not take penalties.

• NAS-410 is more specific as to limitations for a Level I Special.– Some operators use Level I Special as a Level I

which was never the intent.– OEM’s develop procedures with the intent that they

would be utilized by at least a Level I

ATA Spec 105 versus AIA NAS-410



• This workshop was convened to discuss the FAA’s Composite Inspector Training activity. The overall objective of this training initiative is to improve the performance of current composite inspection practices.

• The Composite NDI curriculum can be used by airlines and MROs to enhance an inspector’s preparation and training by focusing on the unique challenges associated with composite laminate inspections.

• The purpose of the workshop was to obtain input on the needs, objectives, content and implementation of the course that we are trying to develop. Workshop participants include airlines, cargo, MROs and aircraft manufacturers.

Composite NDI Training Workshop



• NDI training needs (unique composite inspection challenges),

• Course content (teaching points), needs for hands-on exercises and NDI Proficiency Specimens (training),

• Human factors issues, use of real life inspection cases, • How to best aid/improve NDI methods/procedures,

information gathering needed, • Training deployment and adoption into airline

maintenance programs

Composite NDI Training Workshop



• STC ICA’s involving NDI– 14 Code of Federal Regulations §21.50– Requires Instructions for Continued Airworthiness

• Bonded Repair Size Limits– Inability to nondestructively measure bond strength is a limiting

factor for repair sizes.– Challenge: Means to nondestructively but accuratley measure

bond strength.• Additive Manufacturing

– What are failure modes?– Inspection Challenges

• Encouragement for young people to enter the aviation maintenance profession

Additional FAA Updates:



Why are we here?

• Information Sharing;– Provide information and updates for NDI

• New guidance,– NDI facilities, – NDI training and qualification– NDI Job Aid

–I learn from you!!• What are you experiencing in the field?• What do you see as additional guidance needs?• I value your input!!!!

STS for NDI and Composite Materials Maintenance

Documents

Transcript of STS for NDI and Composite Materials Maintenance