~l-m-38780 (iisap) -...

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~L-M-38780 (IISAP)15 February 1967

MILITARY SPECI~CATION

MANUAL, TECXNICAL: NONDESTRUCTIVE INSPECTION

1. SCOPE

1.1 This specification contains instructions for the preparation oftechnical manuals required for the application of nondestructive in-spection (NDI) methods on aircraft (-36) manual), missiles -d sPaceweapons (-26manuale), and engines (-9 manual). Instructions for thepreparation of NDI methods to be included in maintenance manuals forcomponents and equipment not requiring a separate manual (-36, -26,-9 are also provided,

1.2 The ❑anuals and procedures covered by this epecifioation areintended to provide instructions and guidance to NDI technicians inthe organizational, titermediate, and depot levels of maintenance forthe use of NDI methods on systems, subsystems, support systems adtheir components.

2. APPLICABLE DOCUMENTS

2-.1 Government documents. The following documents, of the issue ineffect on the date of invitation for bids, request prOpOSal, or COntraCtdate, vhiohever occurs first, form a part of this specification to theextent specified herein.

SPECIFICATIONS

MILM-38784 Manuale, Technical; General Requirements forfor Preparation of Printing

NHJ’-3S79O Printing Production of TechnicalManuals: General Aequiremente for

MILITARY STANDARDS

MIL-STD-882 System Safety Program for Systems andAssociated Subsystems, and Equipment,Requirements for

PUBLICATIONS

Technical Orders

00-5-1 Air Force Teohnioal Order System

0~-20-5 Aircraft, Drone and Air Launched Missile FlightReports and Supporting Maintenance Records

33B-1-1 Nondestructive Inspection Methods

Table of Allowances

TA-&i5 Table of Allowance for Nondestructive InspectionEquipment

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(Copies of doouments requtied by contractors in connection with specificprocurement functione should be obtained from the procu.mng activity oras directed by the contracting officer.)

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HIL-M-38780A (USAF)

2.2 Other publications. The followhg document forms a part of thisspecification to the extent specified herein. Unless otherwise indi-cated, the latest issue In effect on the ~ateof invitation for bids,,or request for proposal shall apply.

Nondestructive Testtig Handbook, Robert C. McMaster,ed.

(Application for copie~ ehould be addreaaed to the Amerioan Society forNondestructive Tenting, Inc., 914 Chioago Avenue, Evanston, Illinois6202)

3. REQUIREKEWTS

3.1 Preparation. Ufiees otherwise specified, the general manner ofpreparation of the NDI ●anual shall be in woordauce with MIL-M-38784and MIL-STD-882.

3.1.1 Development of a NDI manual shall meet the indlt?idualneeds ofthe system for which it is intended. Examples of system deai~ conoept~with di.fferenceathat must be considered are: fighter vs cargo vs heli-copter aircraft; and jet vs reciprocating engines.

3.1.2 NDI procedures for components or equipment that will not beextensive enough to justify a separate manual, shall be placed in theinspection section of the applicable ~al. Examples of components orequipment that may not require a separate NDI manual are: aerospaoeground equipment; accessory gear drives; electrical generator;auxiliary power units, etc. Preparation of the NDI procedures forinsertion in the inspection eeotion ehall be in aoaordance with para-graph 3.6.

3.2 Contents

5.2.1 ‘r& iwii-,-uiil -u”]1“u-..~~~~~~e ~ii ~Qnflemtructiveinspection instructions,

procedures, aud techniques for the system or support system concerned.NDI technique6 shall be developed to inspect critical areas of componentsor subsystems for potential servioe defeots (cracking, corrosion, wear,or deformation). NDI teohnique development is required whenever one ofthe following criteria is met: (a) the NDI method improves safe operationor reliability of the system or subsystem, (b) a saving in maintenanceoosts or manpower will be realized by using NM methods, or (c) opera-tional effectlveneas or life cycle oosts will be favorably effected.EJnphasisshall be placed on development of NDI technique that can beapplied on tie system or subsystem with little or no disassembly (on-condition maintenance).. When necessary, multiple NDI procedures may bedeveloped for assembled (on-condition maintenance) and disassembled P~ts.

3.2.1.1 The manual shall Include, but is not limited to procedures coveringthe following methods: penetrent, magnetic particle, eddy current, ultra-sonic, end radiographic inspection. Other methods may be jncluded asnecessary if they will provide significant improvement in inspectioncapability, Proposals for inclusion of methods and equipment not present]yueed should be submitted during and included in the ❑inutes of t@ guidancemeeting paragraph 4.3.1.WDocumentation shall be provided showing why exie.~methods and equipment are not satisfactory and of the Improvement to oeachieved by the proposed method.

3.2.1.2 Routtie visual, magnifying glass, or boroscopic/fiber opticinspections that are normally aocompliehed by aircraft/power plantmeohanios, mall not be included in the NDI manual but shall continueto be included in the applicable ●aintenance/Inspection M_UB1. Specialcases may be included at the request of the using crnsnd(s) based oncomponent oriticallity or of’special preparation or inspection teohniquerequirements. Visual or optical tispections may be included h the manualwhen used aa a verification procedure (ref paragraph 3.2.2) but do notneed to be detailed.

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3.2.1.3 The LU_Wal sh~ll contain detailed step-by-step instructions foreach inspection so that a trained NDI technician can duplicate thedesorlbed inspection. The basic theory and general procedures for use ofNDI ❑ethods are contained in TO 33B-1-1, end the Nondestructive TestingHandbook. The *nondestructiveTesting Handbook shall be used as a guidein the selection and proper application of nondestructive inspectionmethods. Where the instructions contained in the Handbook differ fromthose contained in TO 33D-1-1, the latter instructions shall apply.

3.2.2 Veril’ioation(Back-up) Inspection Prooeduree

3.2.2.1 Each inspection will, when necessary, specify a verification(back-up) inspection procedure by another means to verify the initialinspection results. Verification procedures shall be provided in everycase where the initial tiapection result.ado not provide incontestabledata for determination of the serviceability of the item inspected.

3.2.2.2 It is desirable to perform the verification procedure by amethod emplo ing direct visual observation (optical, magnetic particle,or penetrantf when the initial procedure is performed by an instrumented❑ethod (Xray, eddy current or ultrasonic) providing it does not resultin extensive disassembly. In those cases where direct observationmethods would require considerable disassembly, the use of a differentinstrumented method ie the preferred means of verification. It may bemecessary in isolated tames to disassemble for visual confirmationto provide the necessary information for determination of componentservioeabllity.

3.2.3 Illustrations

3.2.3.1 Illustrations to be included in the manual are specified inparagraph 3.4.2, 3.0, and 3.7. All illustrations shall comply withMIL-M-3S784 requirements.

3.2.3.2 Eaoh inspection procedure shall be illustrated with views ofthe component or subsystem to be fispected showing: (a) general locationof the ins ection area within the aircraft, missile, engine, or supportsystem; (bf specific location of the oomponent or subsystem to be in-spected plus location and orientation of potential defects. This maybe shown in two or ❑ore views as required for adequate orientation.

3.2.3.3 Symbols that shall be used to represent nondestructive in-spection ❑ethods and provide detail in illustrating inspection proceduresare in Figures 1 & 2. Wherever possible the symbol for the primary andback-up method shall be placed adjacent to the area to be inspected inthe next higher assembly Lllus*ration

3.2.3.4 Illustrations from existing manuals (Illustrated Parts Break-down, Maintenance Manuals, etc) ohall be ueed when practical.

3.2.4 Nondestructive Inspection Equipment

3.2.4.1 NDI procedures shall be written in such a manner that Air Forceissued equipment (as listed in TA-455) may be used. In those cases whereAF standard equipment will not provide the necessary result.a(refparagraph 3.2.1.1) other equipment may be used if prior approval isobtained thro

?the procuring activity from the AF NDI Program

Manager (SAAfIIAMMEW, Kelly AFB, TX).

3.2.4.2 Complete sketches specifying dimensions, surface finish, tolerwce,and ❑aterials of all special ancillary equipment (standards, shoes, wedgea,fixtures, and jigs) shall be included as illustrations. The sketches donot need to be actual size drawings however they shall be adequate to permitfuture local manufacture by Air Force bases. The sketches shall beprovided even when an initial quantity of special ancillary equipment isprocured as support equipment.

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MIL-M-38780A (USAF)

3.2.5 Safety. Each inspection procedure included in the manual shallbe developed in compliance with MIL-STD-882. Hazards involved, bothpermonal and ~terial, will be clearly ‘hnnotatedand classified perMIL-STD-882. Where required, general safety precautions and specificlimitations against the use of NDI equipment on operationally configuredaircraft shall be included in Section 1, Genersl.

3.2.5.1 Each radiographic technique shall include the following:

IJARNING

RADIATION HAZARD

Ensure oomplianoe with all applicable safety precautions set forth bSectiwn 1 of this manual and In TO 333-1-1. Failure to comply 9ayresult in injury to personnel.

3.3 Arrangement. The mSZUASlshall ba arranged in the following order:Front matter; Introduction; Sectirm 1, General; Section 11 and subsequentsections. Beginning with Section II, each eection shall contain the in-spection procedures dealing with a major assembly or subassembly. Thesesections shall be arranged in the sw order as ❑ajor sections of theIllustrated Parts Breakdown for the aircraft, missile and engine.

3.3.1 Front Matter. Front matter shall consist of: Cover page; list ofeffective pages; table of contents; list of illustrations; and list oftables. Front matter shall be prepared in accordance with the require-❑ents of KIL-H-38784.

3.3.2 Introduction. The introduction to the manual shall begin with thefollowing text:

1. Thie manual contains instructions for accomplishing nondestructiveinspection of the aircraft (or missile, or engine, etc., as appropriate).The procedures preacri_oea‘by‘&is iiian-.i~l~-e L?$cz&c& tc p?wi~~ etep-hy-step matructions for the nondestructive inspection of locations whereservice defects would prevent the items from performtig their designatedfunctions. These procedures are developed through maintenance engineeringexperience end comparison with similar installations on inaervice equip-ment. They are refined and changes as required during the service lifeof the equipment by continually evaluating the performance of the equip-ment, results of scheduled inspections,amd through study of failure data.Local conditions, such as epecial utilization 01 cM.9atic environment,may dictate more detailed inspections. C~anders and their maintenanceofficers are expected to exercise their prerogative to increane the scopeof any inspection as required.

2. This manual may pertain to part, or all types and series, of’amode1, and may, therefore, oontain requirements applicable to specificequipment that i~ not installed on an individual model. When this situa-tion is encountered, those requirements that are not applicable shouldbe disregarded.

3. This manual does not contain inspection level or frequency,acceptance/rejection limitations, or instructions for correcting defectiveconditions. Inspection levels sndiPequency are provided in the inspectionrequirements manuals. Detailed acceptance/rejection criteria and in-structions for correcting defective conditions are provided in appropriatemaintenance manuals. This information is not contained in this manualsince decisions regarding the serviceability of components properly belongswith maintenance technicians trained, skilled, and experienced in theirparticular speciality, e.g. airframe, hydraulic, propulsion, etc. Alsoit would duplicate existing information and the task of Incorporating thenumerous changes to inspection frequency and repair instructions iaimpractical.

4. The inspection requirements are stated in such a manner as toestablish what is to be inspected, what conditions are to be sought, whatnondestructive i~mpection method is to be used, and how the method 1s to

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be performed. in ●cope, the inspection procedures are designed to directattention of ❑aintenance personnel to components and areas where servicedefeots CSIIOCCUr and to provide detailed instructions on the applicationof nondestructive inspection to assure the integrity of’these areas.

5. Nondestructive inspection methods require application by trained,experienced, and proficient technicians. While this manual provides detailedstep-by-step procedures for the application of nondestructive methods toinspect specific areas or locations, it must be emphasized that the relia-bility of the inspection results depends upon the proper application of thePeadings obtained from the inspection equipment.

6. While using this manual, such adjectives as left and right, upperand lower, front and rear, forward and aft, and clockwise and counterclock-wise refer to the airplane (or missile, or engine, etc, as appropriate) asviewed from the rear, on the centerline, looklng forward. All dimensions,material gages, and distances are given in inches unless otherwi$e noted.

7. Changes and supplements to this manual will be publishe~u$ennecessary to add, delete, or change the scope of requirements.changes will be based on factual data accumulated as a result of Mainten-ance experience with the equipment.developed ins

Suggested new or revised field

Yction procedures shall be ~epared on AFTO Forms 242

(Radiographic , 242A (Penetrant), 242B (Magnetic WC (EddyCurrent), 242D (Ultrasonic), fiondestructiveinspection Data per TO 33B-1-1and submitted as an attachment to AFTO Form 22, Technical Order SystemImprovement Report per TO 00-5-1.

8. These NDI procedures are direotive in nature and deviationswithout prior approval from the prime AMA limited to compensation ofeguipment output. ~uipment settings, when given, are reference pointsonly, due to the widely varying outputs from different machines. Thecondition that must be satisfied ~or accurate inspecticm is that theinspection equipment be adjusted to obtain the specified response fromthe set-up or defect standard or the specifietidensi~y r~ai~-igcm x-rcyfilm. Trained NDI technicians are qualified to make these adjustments.

3.4 Section 1.3 General

3.4.1 This section shall include, but not be limited to subsectionscovering: (a) how to use the ❑anual, (b) neral description of theaircraft (or missile, or engine, etc), (c~table of related manuals,(d) standard symbols, (e) glossary of special terms, abbreviations, andacronym9, (f) general safetY Precautions (ref. para 3.2.5), (g) repetitiveinspection procedures (e.g. standard penetrant procedure= or bolt andbolt-hole inspections), and (h) repetitive inspection equipment set-upor standardizing procedures. Inoorporatien of repetitive atepa inSection 1. will permit reduced text.in the detailed inspection proceduresby reference to Section 1, however it shall not be cause for deletion ofinformation which is essential for a reliable inspection.

3.4.2 Illustrations and tables in Section 1, General, shall include, butnot be limited to: (a) major assembl index, (b) station diagrams, (c) acoessprovisiona, (d) Standard symbols, (ey illustrations required to clarifyrepetitive inspections and calibration procedures, and (f) a table containingnomenclature and p-t, ❑odel, or type designator for all required inspectionequipment and materials.

3.4.2.1 The illustrations listed in paragraph 3.2.3.2 shall be included inthe inspection section of support system manuals (ref para 3.1.2) if theyare not contained in other sections of that particular manual.

3.4.3 The first part of Section 1, General, shall consist of short para-graphs defining nondestructive tiepection and the five primary nondestructive❑ethods. The intent of these paragraphs is to provide non-technical des-criptions for the benefit of individuals who have occasion to utilize theservices of nondestructive inspection technicians. General caution notesshall be included relative tc: the need for qualified NM technicians;

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MIL14-38780A (USAF)

authorization to adjuat equipment settings to obtain theand radiation hazard warning. Figure 3 is an example ofdesires.

3.5 Subsequent Sections

necessary response;the information

3.5.1 Each section following Section 1, General, shall contain the in-spection procedures for components or items in one ●ajor structural group,sectia, or aubayate~. Inepeotione conoem~ a particular part or assemblyshall be grouped together and each inapeotia shall be fully developed anddocumented All instructions must be o~plete so that any NDI techniciancan duplicate the inspection with reliable results.

3.5.2 Each section shall oontain an index listing the components or partsand the respective inspection prooedure. Where prmotical, this indexshall be illustrated with a aketoh of the major asaembly marked to showthe approximate location of the parts to be inspected.

3.5.3 The inspection procedure narration mud its accompanying illustratiwsshall be plaoed am c1ose together as is possible. The illustraticm ehallbe placed behind the narration. When the illustration of a part oroomponent is to be used for two or more procedures, it shall be placedbehind the first preeedure~s narration with the additional proceduresfollowing. The procedures shall reference both Figure and page numbers.

3.6 Inswction Procedure

3.6.1 General. The inspection prooedure narration shall be arrauged hparagraph8 and subpara aphs.

rInspection procedures shall include pre and

post inspection stepti preparation and system securing) that must be accom-plished by technicians other than NDI teohnicimns. Wherever possi~le, thesesteps shall be s~ ized by referring to related matitenanc+emanuals (-2-1,-2-2, -23, etc.). These steps shall be expressed in such a manner thatthey cannot be construed as tasks that must be accomplished by the NDItechnician.

3.6.1.1 The required arrangement, format and content of the Inspectionprocedure is provided in the following paragraphs. Examples are providedin figures 4 through 8.

3.6.2 Title. The first paragraph of the inspection prooedure shall aonsistof the nomenclature of the component or subivystemto be impeoted. Nomen-calture of tbe component or subsystem to be inspected. Nomenclature shallbe consistent with Illustrated Parts Breakdown. p=t .n~o shall beused as required to positively identify the component. The installationeffectivity (when not applicable to all models) of the part or subsystemshall be parenthetically. noted after the title, e.g. Stub L-er~,PIN 5B601 (L52G/Ii).

3.6.3 Part Description. The second paragraph, witi illustrati~, *alldescribe and identify the part or component to be tispected. The followingreformation Shall be ~orided fi the narratim and/or ilhatration.

3.6.3.1 The part or component to be inspected shall be illustrated perparagraph 3.2.3.2.

3.6.3.2 Narration shall include the material and alloy, heat treat oondi-tion, method of ■anufacture (e.e. casting, forging, extrusion sheet, eb.surf- treatments, ooatimgs amd l’iniahes.

3.6.3.3 Concise statement or s~ary of the purpoee or Ihnction of thecomponent or part, including the type of loada.

3.6.4 Defect Desarlption~ The third paragraph shall be a narrativedescription of the probable defeot and its oauee. The defeot lmati~ *allbe cross hatched or otherwise high lighted on the illustrated (ref para 3.6.3and 3.2.3.2). Orientation of the defeot shall be depiated by a distinctiveline in the high-li@ted area.

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3.6.5 Inspection Procedure. The fourth paragraph shall consist of thetitle: MIVLIIMY METSOD - ULTRASONIC (or other applicable NDI method)”.The title shall be Oapitalised for emphaaia. The following subparagraphs,lettered rather than numbered, shall be prooeded. Note: The radiationhazard warning, paragraph 3.2.5.1 shall follow the heading when theprimary method is radiographic.

3.6.5.1 The first subparagraph shall be titled nNDI Equipment”. Thepapagraph shall list all equipment, materials, standards, shoes, wedges,fixtures, jigs, films, screens, etc., required to perform the”inspection.StandaPd NDI equipment and materials shall be designated by nomenclatureand part number, model, or type designator. Illustrations specifyingdimens%ona, and materials of all apeclal standards, ahoea, wedges, fixtures,and jl.~sshall be included (ref para 3.2.3.2). When a standard, shoe,wedge, fixture, or jig ia used in more than one inspection, the illustrationdoea not require reprinting. The illustration shall be plaoed behind thefirst procedure while subsequent procedures shall refer to the illustrationby Figure and P- number.

3.6.5.2 The second subparagraph shall be titled, WW!paration of Ai.rOraft(or Missile, or Engtie, aa applicable)n. The narrative shall describeany preparation neceaeary, such as: Lower flaps; jack airoraft; removeoompreasor caaing; etc. Wherever possible, the applicable maintenancemanual shall be referenced, a8:wRemove electronics bay forward raok PepTO lF-4D-2-12 para 6-187.” When no preparaticm ia necessary, the state-ment, ‘No special preparation requiredn, shall follow the title.

3.6.5.3 The next subparagraph shall be titled ‘lAcceasn. The narrativeshall describe how aocesa to the oomponent ie gained. This may be assimple as providing the name and location of an access panel or by statingthat aooesa is gained with rudder in full rkght position. In those caseswhere the item to be inspected is on the exterior and where acoees isobvious, the subparagraph may be omitted.

~.~?i~.~ The next aubparagraDh shall be titled ‘preparation Of pwt”. Thenarrative shall provide information on *at steps are necessary i.oprepki%ethe part for inspection. ‘l!hIaInoludes any coil removal, degreaa~,diaasaembly, or repainting. Wherever possible, the narrative shallreference the detailed maintenance manuala for explicit instruction.Caution or warning notes, where applicable, relative to posulble damageehall be placed ahead of this subparagraph.

3.6.5.5 The naxt subparagraph shall be titled WDI Equipment Setttigs/Standardization/Set-Up”. The narration shall include the specific atep8for uniform net-up and standardization of the NDI equipment for thespecific inspection. General procedures oontalned in the equipmentoperating ❑anuals need not be repeated in these tiatructiona. Repetitiveinstructions shall be Included in Section 1, General and referenced inthis subparagraph. Specific data to be included for eaoh NDI method areprovided in paragraph 3.?.

3.6.5.7 All inspectia procedures shall oonclude with the following state-ment ae a subparagraph: %srk defect(s) mnd record per TO 00-20-5. SeeSection 1 for approved marking materialaw.

3.6.6 BaokuP NDI Prooedure. The fourth numbered paragraph shall describethe verification or backup NDI prooedure (ref paragraph 3.2.2). Allinformation required in paragraph 3.6.5 and its subparagraphs mall beprovided except the title shall beWBMXUP NDI PROCEDURE”. Immediatelyfollowing the title, the conditions under which the verification procedureis required shall be specified. Subparagraphs that are identioal to thosein the Pi.mary prooedure may state, wSame ●s for Primary PreeedureW,without repeating the complete subparagraph.

3.6.7 Sy@tem Searing. The final paragraph in the inspection prooedureshall desoribe the securing and reatoratia of the oomponent or subsystemand aircraft (or missile, or englme, etc). l’hiaparagraph is titendedto provide only general requirement and shall reference the applicablemaintenance manual for detailed Instructions pertaining to restoration

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of the ayntem to an operating configuration.

3.7 Specific NDI Method Data Reauirementa.

3.7.1 General. The following minimum information shall be provided ineach inspection procedure as outlined in paragraph 3.6, InspectionProcedure. All formation shall be presented b step-by-step narrativeform with illustrat%on8 for clarity. Standard NDI symbols (attachment 1)shall be used to show NDI equipment placement and usage.

3.7.2 Penetrant Method Requirements.

Inspection procedurePre inspection repainting and cleaning

;: Penetrant ❑aterial type, sensitivity, and limitation3. Method of application4. Dwell times for penetrant, emulsifiers, and developers,

including temperature at which dwell times were developed5. Lighting requirements6. Ma@fication (if required)7. Post inspection cleaning

3.7.3 Magnetic Par*icle Methti Requirements

lnapection procedure1. Removal of all magnetic sensitive equipment from area beinginspected.2. Pre tispection cleaning3. Method and type of m

Y’etic field (longitudinal/circular/

central oonductor/AC or DC .4. Method, type, concentration, and color of inspection media(wet/dry/continuous/residual and powder color).5. Method of medis application (if pump and hose not used).6. Direction of magnetic flux flow. Illustration shall showthe magnetic field in relation to the defect.7. Amperes of magnetizing current (meter reading) or ampere turnsof current required. Time and number of ahota. Number and elzeof coils or cable 100pa used for longitudinal magnetization.8. Directions for placing item in contact, loop or coil size,placement and spactig of probe legs, placement or location ofthe coil.

Location and cause of false indications (if required).1:: Ma@fication (if requtied)11. Demagnetization procedures, includfig procedure for cheeklevel of residual ●agnetization. Include ●cceptable level ofresidual magnetization.12. Post i.nspeotioncleaning.

3.7.4 Eddy Current Method Requirement.

NDI Equipment Settings/Standardizing/Setup1. Refer to Section 1, General, For equipment setup procedureticluding adjustment for sensitivity and liftoff.2* Step-by-step prooedure to obtain desired meter deflectionfrom defect standard or set up bl-k. Instructions for manu-facture of standard or blook shall be incluciedper para 3.2.4.2.

Imapeotion prooedure1. Area to be noamned, number!of passes, probe **slatiOn, *dscan rate (narrat~ve and illustration(s) showdng tisPection -E’and probe pleoement).2. Defect response and poesible nonrelevant indications, such asedge effect, fasteners, etc.

3.7.5 Ultrasonic Method Requirements.

NDI &uipment Settings/Stmd8rdizi.ng/Set up1. Refer to Section 1, General For initial equipment eetup adsensitivity levels to provide a starting point for subsequent

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adjustment.2. Step-by-step procedure for equipment adjustment to producedesired response from defect standard. Illustrated, as required,to show adjustment of sweep delay, sweep length, ❑arkers, andresponse amplitude without reference to dial settings.3. Illustrations of the cathode ray tube presentation ❑ust showresponse signals in relation to transducer location. Changesin response signals with transducer scanning must be illustratedor described.4. Instructions for manufacture of standard shall be includedper para 3.2.4.2. The standard shall reflect a sensitivitylevel adequate to detect size considered rejectable by theapplicable technical manual.

Inspection procedure1. Area to be soanned, application and type of uouplant, trans-ducer movement, defeot response and possible nonrelevantindications. (Illustration (s) shall show defect response andnonrelevant indications correlated to transducer positions).2. Post inspection cleanhg.

3.7.6 Radiographic Method Requirements.

NDI Equipment Settings/Standardizing/Setup.1. Description of film, claas or type bsaed on signal-to-noiseratio (T(.)33B-1-1), size, and type of packaging, i.e. day-pack,lead pack, or cassettes.2. When more than one film is to be exposed, the number shallbe stated and film placement shown in the illustration. Whenmultiple film technique is used, enter the film type nearentthe Xray tube, a slash mark,followed by the second type film.3. When special cut film or odd ahapes are to be used, adimensioned sketch of the film shall be provided.4. The followin~ i~~yrmation shall he provided on theill-ust.i-~ticr,(s,: .~+iiipl~ceaefitcz ‘~!..eesztpcxn$fitW s3ub9ys?e!!to be inspected; atiing point plus two dimensions for location;and location of the source. Three dimensions are required forsource location including the focal point to film or focuspoint to aiming point. Angles shall not be used. All referencepoints for locating the film and tube head must be easilyrecognized on typical service confi

rred aircraft, mlasile, or

engine. Stenciled reference points body stations, exteriorbulk-head lines, etc.) and rivet or other flush fastenera maynot be recognizable on in-service systems.5. Reference equipment settinga, i.e. Kilovoltage, milliamperage,and exposure time. IndAcate whether film was hand or automaticprocessed and type of processing chemicals used at theseequipment settings.6. Required density in H & D units and area 6n film where densityis ❑eaaured.7. If required, penetrameter location.

Inspection prooedure1. Step-by-st.p inspection procedure.2. If required, special film reading requirements (lightintensity, magnification,etc).

4. Quality Assurance Provisions.

4.1 Production Quality Control. The contractor shall maintain a qualitycontrol program which is adequate to Insure the end product meets therequirements of this specification and ~L-111-387S4.The Government reservesthe right to review and perform any inspections deemed necessary to assurethe manual conforms to prescribed requirementa.

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4.2 Verification of Procedurern. The contractor may develop NDI proceduresh the test laboratory using mook-up or simulated components or parts.However, all Inspection procedures shall be verified on n aervioe configuredaircraft (or missile, or engine, etc) prior to the final draft of theprooedure, F’ollow~ verification, the proposed procedure shall be reviewedby the contractors engineers.

4.3 Guidance. b-process and Prepublication Review Meetl.ms.

4.3.1 Guidance MeetinK. The contractor shall aohedule a ●eeting followingcontract awar~r to starting work on the NDI manual. The purposeof this ❑eethg is to promote a better understanding between the Air Forceand the contractor of their respective obligations by exohange of view-points through personal discussion. This interchange of ideas willfamiliarize the ocmtractor with Air Force field and depot maintenanceprocedures and will provide Air Foroe partloipante with a detailed knowledgeof the contractors proposed work effort. Information obtained throughthis verb41 interchange is not possible to obtain through written communicat-ion. This meeting and the subject.❑atter shall not modi.fy.orohsnge inany manner any of the existing contractual obligations except ae authorizedby the Contracting Officer in writing. The contractor shall noti~y theprocuring activity and SAAMA/MMEW-4 at learnttwenty one days prior to theactual meeting of the saheduled date and location.

4.3.2 Jm-Process and Prepublication Review MeetinRs. In-prooess andprepublication review meetings shall be held in accordance with NIL-M-38784.The contractor~.vproposed schedule for in-process and prepublication reviewmeetings shall be an agenda item at the guidance ❑eeting.

5. Preparation For Deliver~.

5.1 Packaging, packing, and marking for shipment shall be in accordancewith MIL-M-38784 and MXL-P-38790.

6. Iiui.eu.

6.1 Intended Use. This specification is to be used in the preparation ofNDI manuals covering aircraft, missiles, engines, and their supporttigsystems (see paragraph 1).

6.2 Definitions.

6.2.1 Nondestructive Inspection (NIII). A family of methods for investigat-ing the quality , integrity, properties and dimensions of ❑aterials andcomponents without damaging or impairing their serviceability.

6.2.2 On Condition Maintenance. Application of inspection and testingprocedures and techniques without removal or disassembly that allows thecondition of the equi

Tent to dictate the need for maintenance or the

extent af the repair overhaul required to restore serviceability.

6.2.3 NDI ‘technician.Individuals who have been trained in NDI (completedthe 3 or 5 level ATC NDI training ooume or equivalent per TO 33B-1-1)and have demonstrated a satisfactory degree of’NDI proficiency.

6.2.4 Critical Area. Determination of critical areas or components isbaeed on (a) safety of flight considerations (primary structure and non-redundsnt subsystem components the failure of which could cause 10SS ofthe aircraft, missile, or crew), (b) miesion essential considerations(secondwy structure and subsystem components the failure of whleh woulddegrade the ability of the airoraft or missile to perform Its ❑ission),or (c) maintenance economy considerations (structure and subsystem componentsthat would require extensive or repetitive disassembly to perform visualinspection of internal areas). Critical areas are not necessarily limitedto structural components; all subsystem components must be analyzed forcriticalllty.

10


..)

MILI-M-38780A(UaAF)

6.2.5 Discontinuity. Break or interruption in the normal physical structureof a material or component. Examples are cracks, voids, inclusions, andlaminations.

6.2.6 Defect. A discontfiuity or dimensional change which degrades theserviceability of the part.

6.2.7 Nonrelevant Indication. An equipment responee that 1% due tofactors other than discontinuities or defects.

Custodian:

Air Force - 16

Review Activities:Air Force - 01,10,11,82

Preparing Activity:

Air Force - 16

Project NO. TNSS F352

,

—


MIL-M.38780A (USAF)

NDI METHOD IDENTIFICATION SYMBOE

OR

RADIOGRAPHIC

PENhTRANT

i!iNH

ULTRASONIC

MAGNETICPARTIC~

EDDYCURRENT

Figure 1. Symbols Used to Indecate the Primary and VerificationMethod of Accomplishing Nondestructive Inspection.

12


MI&F1.38780A (UaAF)

1-

NDI PROCX ILLUSTRATION SYMBOM

RADIOGRAPHIC

@

8

OR7

\

@

/~\ Aimim:

Tubehead Plaoement

MAGNETIC PARTICU

K0 0

*“ 000 e00 ;

Hand Probe

)-

General PurpoeeProbe

RadiuBProbe

Film Plaoement

LongitudinalTransducer

Shear WaveTranaduoer

Dolt - holeProbe

Figure 2. Symbols Ueed to Provide Detail in IllustratingNondestructive Inspection Procedures

13


SECTION IGE31hWiL

TO lC-5A-36

1-1. NONDESTRUCTIVE INSPECTION.

1-2. A family of methods for Investigating the quality, integrity, propert-ies, and dimensions of materials, and components, vlthout damaging orimpairing their ●ervioeablilty, by une of penetrant, ~tic partLcle,eddy current, ultrasonic, radlogra~ic, etc, Inspections.

Effective utilization of NDI can be attained only by trainedand experlenoed personnel.

1-3. NONDESTRUCTIVE INSPECTION llElllOIS.

1-4. PENETRANT INSPECTION METEOD. (Refer to TO 330-1-1, Chapter 6.).Penetrant Inapeotion is a nondestructive test for disoontinuities open tothe surfaoe in parts made of nonporous materials. Thi8 is done by treatingthe whole area vith a fluid which penetrates into the surface disoontlnuity.Tbe surplus penetrant, not in the discontinuity is removed and the penetrantremaining in the disoontlnulty in returned to the surface by capillaryaction. A developer is applied to provide a oentraat~ surf’aoeand -o@absorption forms an Indication large enough to be noticeable to the eye.It is a quiok and positkve method f’ordetecting many different types ofeurface disconttiuitiea. Its ohlef limitations are that discontinuitieamust be open to the eurfme and it ia essential that there be no contaminat-ing material around or in the diooontinuity uhich might either preventtfiepenecranc frum euLt41-h~“thedd’ect ~r kiick =Cy FelXJceite YiEitlilit.y,Visible dye penetranta have the lowest sensitivity of any penetrant -dare not to be used for the i.nspeotionof servioe defects on aircraft,missile or engine components.

MAGNETIC PARTICLE INSPECTION METHOD (Refer to TO 33B-1-1, Chapter 2).~etlc perticle innpeotion is a ropid nomdestruotive means or detectingdiscontfiuities in materials having ferromagnetic properties, principallyiron and steel. Magnetic particle Inspection is aooomplished by inducinga m~etic f%eld into a part. A defect will titer~pt this f%eld oreat~new north and south poles with the magnetic flux brldglng the defect. ‘hisflux liakage attracts the ma@etic particles to form the indication. Inaddition to oraoka, the types of flaws that oan be detected include aeons,laps, folds, end nonmetallic inclusion that are either surfaoe or slightlysubsurface.

1-6. IIBDYCURRENT INSPECTI.9NMETllOD(Refer to TO 331L1-1, Chapter 2).Eddy current inspectim is a nondestructive meane of obtaining informationa number of material variables such as alloy type, hardness, heat treatcondition, thiohess, araoka, etc. An insulated ooil induces eddy ourrentsby being plaoed in close proximity to a conductive tent pieoe, Surfaoe ornear surfaoe disoontinuities auue a major disruption of the eddy currentfield, thus produoing a detectable ohange. These ohsmges oan be read outon a meter, cathode ray tube, or recorder.

1-1

-e 3. Ex-ple of Information Desired in Seotion I.(Sheet 1 of 2)

14


MIL-IL3s7130A(USAF)

TO lC-5A-36

1-7. ULTRASONIC INSPECTION METHOD (Refer to TO 338-1-1, Chapter 4).Ultrasonic inspection is a method of inspection, using sound waves abovethe audible range. High frequency sound is induced into the part by atransducer. This ultrasonic energy travels through the part. Any markedchanges in acoustic properties (flaw,interface or back surface) willreflect the sound back to the transducer. This information is normallydisplayed on an oacllloscope. Proper selection of transducer, fpequency,sensitivity, angle, etc, will enable inspection of the surfaoe~ subsurface,and baok surface of the part.

1-8. RADIOGRAPHIC INSPECTION METNOD (Refer to TO 33B-1-1, Chapter 5).Radiographic inspection is a nondeatructiva inspection method utill%inga source of X-raye or gma rays to deteot discontinuities in materialsand components. X-rays penetpate metallics and nonmetallic and aredifferentially abaorbed. Discontinuities, which are less dense than metalabsorb less radiation and thus are shown on the recording medium as darkshadows. The recording medium, for the purposes of this ❑anual, is rihbut it can be any means that converts radiation energy into a visible image.Radiography is used to inspect both metallic and non metallic ❑aterials.It has the capability of inspecting the interior of opaque objects orassemblies without acoess to the inside. However, the defects must bealigned and oriented with Pespect to the X-ray beam and film. Radiographyis,one of the most expensive and aeast sensitive test methods for finecrack detection ad should only be used to deteot flaws whioh are notaccessible or improperly oriented for the use of other test methods.

NOTE

There ia considerable variation in equipment output withrespect to numerical s~tttigs. NDI technicisna are required4.u. COiiipeKZS2tc for the Wwiat.inns to produce the necessaryresponse or densities. (Refer to TO 33E-1-1).

1-2

Figure 3. Example of Information Desired in Section 1.(Sheet 2 of 2)

—15


MIL-M-38780A (IEdlF)

T*O.lC-5A-36

I

I

I

6.126. VISOR DOOR BULKREADRING.INNERLEG.FUSELAGE STATION 281, DRAWING4 F73790.

6-157. DESCNFT30N. [See figure 6-28-6/0.) Tirevieor &or bulkhead ring is located at fuselagestailon 281. The Imlkhead ring is made from a?075-T8 shnniraim extrudmr sod is given a cAemIcalconversion coating and two mate of zinc chromateprimer. The rhg is attached to the tadkbaad PSOSLbaa beam and intercostal ●ttachments, traversesseveral panel splices and has seven splices of itsown.

6-158, DEFSCTS. OveI’3oadatreaaesuw saraentrateat rlog and panel ep3ices end at the beam attachregi~ poeadbiy resultiag 10 craOk8 ~ IO theframe ElJot radius,as illustmtad in figure 6.29-6/0.

c. Access: Inspustion areu ●re &Cces.etblefrom tn-~ide the carzo compartment wtlh forward ramp innormal closcrl POsftioo. hrafrectkm *U require theuse of AOS platforms10r*]~~ W* ~ @-@SidetfuSirphoe.

d. Prspantion of park No qnsid prsparafioo re-QUhd

e. X-my machine aettin@: SatX.ray mwhtne fortechoiq4* kkated In ~c~-~ock in fiwre 6-28-6/0. ma wOeadUW b f= ●

ft3m-!Y of 1.8 to S.5.

6-159. P2UMARY NDI PRGcELxfR& - RAmo-GRAPHIC.

Refer to t$ecticm I for - ~~-Uon instrutiaua.

wAGiclIm6

RADIATION WAZABD

Ensure complhnte wltb all epptt-e safetyprecautions set forth in Seetkm I of thismanual and in T.O. 33B-1-1. Failuretacomply may remit in tojury to peracemel.

a. ND] equipmen~

(1) X-ray MacJune, Fertable, lffOfCVF, 40 degreetube bearl, SperryP/N SPX-160E-8-Cor equlTs3eDL

b. Preparetton of airplane: Remove UM nose radomeand inaulatimr blankets, in accor*@ *~T.O. lC-5A-2-2, section IL Ramwe ttre forwardrSMPCSteiISiOYIin●ccordancewithT.Cl.1C-5A-2.12,section IL

WARMIH8

f. Yllm plaoemmt P18ce X-ray film on tire forwardaide of the *r door bukbaad ring inner loguilluetratsdin !@ure 6-2B-6/O for exth erqmswe.*r= ~. removatbs eaposedtitipwfilm for the next eapmrre. Use film ~cilied inRadtosMPMc lrqsotioo Data in x 6-26-6/0.

g. X-ray tuta looetiom Lac.ata the X-ray tuba asilhiatratedin figure 6-28-6/0 for each espoaure.AftSr exposing ead film, rdCC?@ the tube for thenexl ~rq as ilhstraked in figure 6-28-6/0.

h Inapeotkeu Make mdiograptu of me nsor moor~ rwghmar lagiasoemkK@ titbtbenumber.ed esposuree illwtreted as indtceted in’ tbs ~m-aohtc 3nspecUrsi Data in fiwe 6-2&9/O.

i. Mark and repori indfcatedddecta. See Sectton

I lor approvedtar+mry ~ **-

Prior to ●ppreacidog tba @aor door, disableall visor door operettng systsms in ac-

6-161. SYSTEM SEcumc. Claarl area in8Pec@

cmdrmce with T.O. lC-SA-2-12, 2ecUmI II.restore fiaisbaa, reinstallre=~ oom~m, ~d

FaUure to comply may remUt in lapiry toperform opemticeral cbe~, m re@r* in a~

peracemai,eorrtanoe with app21UMe T.O. ‘s.

6-72

Figure 4. Exmmple Or Format and Content of ~~o=a~cInspection prooodures. {Sheet 1 of 5]

\

16


1-

—

MIL-FL38780A (IhAE’)

T.O.lC-5A+8

WL,~lSKIN

LSG

‘ D’TYP FILM

II

rLAcEMENT ;

‘Dfus~

I

WL 274--——— ——. -

__— ——- --

WL 214---

WL lS9-

WL M4--———— —_~

WA=. . ..-

FWORAMP

b

IllsFuS

SAA STA

LOOKING INIKJ So7

4s

Fipm~ vbunoorhM80dRkekb%~- ssl(shdId4)

Figure 4. Example of Format and Contant of RadiographicInspection Procedures. (Sheet 2--or”5?

6-7S

1’7

—


MXIA1.38780A (~~)

r.o.lc-SA-36

I

n

18L,0

. . . la LU )8

14

I-,””-.— ..............--- 1 .

1 I I n\

[

WL ’274 ;

PMCEM2M ONFRO~ OF RING

Ii EmFILM PL#CEMEPW

FlLMS2Aj &M4DSAMEF~

INNER LEGRING SPLICE00 USLUS

LOOKING MlANO REQUIRE A SEPARATE

FLIS STA 281●’XPOSIRE

LEFT SIDE SHCWN;RIGHT SIDE OFFOslTE

~gure 4. ~xMPle of Fe-at and Content of Radiofla@c

Inspection procedues.(Sheet 3 of 5)


MIL-M-387#30A(USAF)

,-

)-

Fus ISIA sml 3

‘./-’

SLO

L& lo—

f MM

Lu6z—

I

FMSTA

+==

I FwD

I

C=J

1.0.1 C-SA-M

&A7

—

—u 11s

—u 115

LET SIDE ssimwRIOHT SIDE OPPOSITE

F’igure4. Example of Format and Cmtent of Radiogra~cInmpaotion Prooedsss=es.(Sheet 4 of 5)

19


MIL-M-38780A

1.0. IC-SA-36

(uaAF)

7

EXPOSURE

NUMBERKV

130

150

150

15D

150

150

150

150

150

150

150

150

MA

4

4

4

4

4

4

4

4

4

4

4

4

RADIOGRAPHIC INSPECTION DATA I

$FD [INCHES)

70

120

120

120

12Q

120

120

120

120

120

I 20

120

TIME(Sfcl

130

180

210

)00

180

210

180

2) o

180

180

180

I 80

-Jx RWARKS I1 ,

B 7X24 FILM NO. SAME ASEXPOSURE NO. 1

B 17x50 I I

A lox 12

B i7x30

8 7XM

A lox 12

8 7x32

A lox 12

B 7x34

0 7X40

B 7x2a

FILM SIZE IS [email protected] FILM. 7X17REGuLAR SIZEFILM MAY Bf USEDIF DESIREO .

B 7X24

w.~4t14 +

fiQuro 6-284/0. VicoI Dow Rulkhed R+, kwtw bg, fwdww Stdaa 2S1 (Sbd 4 d 4/6-’76

I’igwe 4. fiample of Format and Content of RadiographicInspection procedures. (Sheet 5 of 5)

w


r-

MIL-M-38780A (U~AF)

T.0, IC-5A-36

7--

6-222. VfSOR DCS3R SIDE LATCII HOOKS, WATERLINE 306, DRAW3NGS 4173300, 41=13710,42=7371?, 4n3114, 4F7371G, 4F73718,4F73720, 4~3722 Af4D 4P73T24.

6-223. 13ESCR3PT30f4. (See figure 6-40 -2/0.) Thereare sixteen latch hooks located in the forward fuse-lage, eight hooks each located on the left and rightsides at Fuselage Stsbon 310, 330, 350, 375, 398, 416,443 and 464, and Water I.JIK 306. The latch hook ismade of PH13- 6M0 steel, heat Wea,tcd to zoo Km.The hook has a serrated back face and slotted holeswluch Alow for matmg with ths asrrated plate andeuteedaetnry fmeltmrung of *S ~ywhenhookand spwl are engaged.

6.224. DEFECTS. possible misal@ment of the vieorCould cause excessive loacttng m ths ~ lesdingto cracking inside the hook radius.

6-225. PRfMARY XDI PROCEDURE- FLUORESCENTPEJ4ETRANT.

a. NDI equipment:

(1) Fluoreeccnt penetrant materials snd equip-ment 6eleCtSd from approved list b tawe 1.~.

b. Preparanon of al~lanw Open the naor clbor inaccordance wlb the instructions contatned in T.O.lC-5A-2-12, Section II.

,c. Access: Inspection areas are accessible with theViSOr door open. Use ACE platiorms for eievation.

High strength steels are extremely sus-ceptible to hydrogen embrttUement causedby acid-base cleaners end solvents. Useonly Ciesners and solvents that are eefifiedsafe for use on high strength steel parts,P&lure to soroply may csuee cnrksin parte.

d. Prepwation of part: See T.O. lc-5A-23, secnonV, for finish removal/rsatoratton and cleardng in-structions. Strip finish from logssl eucpected defectiveareas. clean local inapecticm areas.

e. 3natnonmt aefflnga/ca3tta’attmNol appllsable.

f. fnapection: Perform flooreacent penetrent inspec-ti~ ~ SCCOrdSIICe tith able l-f. Section ~ andinstmctions contidned in T.O. S3B-1 -1.

g. Mark and report incbealed defects. See sectionI for approved teznpo~ marking materials.

8-226. BACKUP 34DI PROCEDURE. None rertuireci

6.227. SYSTEM SECURD4G. Clan areas inspected,restore finiahea, reinstall removed components, and

perform operational checkouts, se required, in ac-cordance with applicable T.O. ‘s.

7-

6-120

Figure 5. Example of Format and Content of FluorescentPenetrant Inspection Procedures. (Sheet 1 of 2)

21


I

I

I

!

I

I

I

v&moKWcn

to. ?C-SA-*

4’

n“LHl SUMsnow,RH SIDE OrrOSITE

Ra19Tuo-am vss Daf*w-w--wm 6-lal

Figure 5. Example of Format ‘andCsmtent of Fluore@o~tPenetrmt Inspemtim ProDedmen.

(meet 2 of 2)

23


i

HIL-M-38?80A (USAF)

K.O. lC-5A-36

I

I

1

8-S73, FORWARO IUMP EXTEN.910N AFT BEAMIIINGE, DRAWIN02 4F52111 ANO 4F?i2817.

6-374. DESCRIPTION.(See flgurc 6-70-3/0.) Eightmachined I@ strmgth sieel hioges attach the forward~P OlltOOSiOnto tiM forward ramp atnwture. Thesehioges, locsied on the aft besm of the fo= rqmpSxtenaioq am Mdmium-tttmtum Slioy plated-painted with zinc chromste ptimer.Tiu4F52111hinges are msdefrom4240allq steel best tre8ted to200.220 KS uitimate tensile strengih, and are usedm awlane# eeriaiiaed through AF 87-174. The4Pd281’1 ~e, fad cm dr@aaea rnria21aedAF 68-211 sod q am maouiaeturad fran 174 PII~t.ainleae steelbeattreatedto190KS2uMmate2en-etleetrength. Thetwvtypee ofhiogeo arestmiiarill eoo2i@rafMro.

6-S75. DEPTKM. EoM02rIc loadiqr of b MMP aridmom extenaioa dtiK ee-ca OPSratime odd oaueeomr4rsti ~2mtm~s2heh 2esteaar -

Nolo

Two primary ND, Pmoedum - P~No. 1 for the 4340 alloy steal Ida@% andNo. 2 for tbe17-4PH ehhdeee 8&el Moree.

6-276. PRIMARY NDI PROCEIXIRC No. 1- MAGNEITc PARTICLE.

L NDI ewipmaew

(1) Magnetic Inspection Ikdk 1~-ioctk ‘&POM&a, ww aropemq or ecpunimn~

(2) Fluoresemt Megaettc Partieie Materials.

b. Preparation of si~lane: Remove forward ramp ex-teaslon from th sirpime in eemrdeme WithT.O. lC-4A-2-12, ~mll. ~ eipht~a frantherarop eatmaicaa?tofbeamin~ withT.O. lC-5A-2-12, 3eetion L

c. Acooaw bsPoC4b0 areas are SCOOSd~ dih *monia &scriiredin etsp b aixme amompliskl

EEEE3Hi@ etren@ steeis are extmmeiy m!acePti-ble to fIydrogen erobritilemmt oausedby acid-imee ciemers sod eoivwrtta. Uae miiy eiemersand eoheots that am certified safe for useon highetrmgih steel ~. Fatlura toecmplymay fauee~inparta.

d. Prepantton of pam See T.O.lC-5A-23, IlecttcmV, for cleaning In@metiona. Clearl ittngee of cUn-2amimia2e tbAt could tmerfore with ememtrat2m otmagnetic parwAee At dsmoumduee oroatteeim-pmperamwdeUm otparUieh

e-m

e. fnatrument Settingdc.alibratiottCdibratiOo 00tapplicable. Set selector ewitcb m udt (or dlreeteurrmt power mtqly. Ad@sl Ouruot ea -%

(1) Circular field 1600- 2CO0amperes.

(2) Ue@tudioel Iiel* 1200-2000 -~ ~tin Cdl.

L2eePeeUoWH*p~* wetemti9mrMMacoetic particle methr4 ~ both eircuiar andIoogtiudtoal magnetic fiel* in ●mordaooe withT.O. 22F&i-1. ~fi.ntv=’U -m~of

~.

g. b2arkaed r8Porti@oated *fee@. *~1torappmTedtmopWuT ~ --

6-277. PRIMARY NDI PROCEDURENO.2- FLU*ORESCENTPZNETRANT ?OR17-4PRST~-W STEEL

a. NDI Sqlripmmt

(1) Fiuoresemt peoetrmt matemais S@ e@utP-meot selected from approved iiat in tabie 1.m.

hpreparstimofalapiane:-e~k~NDIProoe&reNo.1.

c.AOMU: SSIOOaSiOr P?iOWYNDI~NQ.1.

1====’1

High etrmgth steels are ~y suecePii-ble to hydrogeauabritilement Oausedhyaei&hee eieamrs mdeoivents.Ueemiy elesaeraand eolwota tint am ~rttfiod SS20ior usemhigb~etee2psrta. PAiMretOSa@Jmaycalue eracksio parta.

& ~ratioo of pare eee T.O. lC-CA-% SeatimV, for fioish remOvai/reatOratiM i_S2tMS. SrOiirdab frmll hcai mupmted &2eedTe areas. aaeloosl Illq!ectim Sresa.

e. IOetmment ~- ~.

f. WCdotx perform flwreeeeo t PmetrantvUrn procwbwe per tabh l-lIioSeCUatIiO ~wlfb ~ omtaioed 10 T.O. 22B-1-I.

g. Markand reporriodiated defome.2ee~2for Spprvveet ~ marMog mat*rIaiA

2-378. 8AmP Nm PROCEDURE: Nma q@-

6-9’/9. 6YSfZb2 2ECUIUNG Ciem areas ~~restore 2ittteitea, retoetW remowd~-perform Opemtimai aeoKnrq ss~iose.~ uitb a#ieabLe T.O.’A

Figure 6. Example of Format and Content of MagneticParticle Inspection Prooedurea. (Sheet 1 Of 2)

‘) 23


mIL-!4-s8?73eh(mm)

7,0. lC-SA--

. .35

Y tkJRlw\”Ew

/

?3TYPICAL FWO RAMP EXTEN90NMT WAM mNGE ASS~y.WCWAL (8) _f$Jo

mt#E ~

moMBLOCATIORlell

III

b-2tl

Figure 6. Example of Fornat and Content of MagnetioParticle Inspection Procedures. (Sheet 2 of 2)

—


ML-M.38780A (mm)

‘-)

I

.

,p-1 )

I

7.0. lC-SA.36

6.360. FORWARD 37AMP EXTENSION LONGXTUDI-tiAL f3EAhl ,WD AFT HINGE FITTIXG AT-TACH POfNTS AND ACTUATOR ATTACHPOtSTS, DRAWINOS 4F5219S, 4F52136, AND4F52i37.

6-381. DESCRIPTION. (See figure 6-71 -4/2.) Theej ght forward ramp extension aft binge ffttinga areattwhed tO the Upper rear arsaa of fhe ?= CX-tension lontoturlinal beams. TWO Of the hinge fittingsserve m anchor points for the fomard ramP ex-tension actustor fittings. The beams are macfrirrsdfrom 7075-T65 I aluminum alloy, are mdfurkc addanndtzed sort painted with two OOSteof stoc cfucmrateprimer.

6-382. DEFECTS.The stich potnta on the beams areexposed toatmospheric conditAona, end high stressesdurlug airplane loading and urrloarfhrg operations.Cracka may orlglntite radiating from the truss barattach bolt hole in two of the besm6 - from Uowenut retaining trdes in ●ach beam.

6-383. PROdARY NDI PROCEDURE - EDDY CUR-RENT.

s. NDI ●quipment

(1) Crack Detector, Megnsfk 3.!D-520 or equiva-lent.

{2) Probe, Bnlt Hole, 3/8-incll to l/2-lrrch dts-meter, MagnsfIua PIN 2008S2 or equivalent.

(3) Probe, Bolt Hole, l/2-inch to S/E-Inch Ma.meter, Megnsfhm P/N 260853 or equfwafent.

(4) Probe, Bolt Hole, 5/8-inch to 1-inch diameter,Magmfhis P/N 2008b4 or equivalent.

b. Preparation of eisplsne: Open visor door in ac-cordance wtth T.O. lC.5A-2-12, Sseticm If.

c. ACCSSS:hrspectfcm areAs are ●ccessible wfth re-movala descrtbad in step b, and vieor dwr open.

d. Preparationd PS* Removeforwardramp htnges,one M a time, and attachment tsmrel nuts andactuator strut (2 places) in accordance wkthT.O. 1C-5A-2-12, Section IL Remove strut andactuator attach fffflng per T.O. 1C-5A-3, SectionIV. 6ee T.O. 1C-5A-23, Section V, for claantng in-stmetinna. Clean lad inspection areas se necessaryto permit good sontact betuean part and probe.

e. Instrument u4tir@calibrattom See paragraphtitled Eddy current Instrument CaUkeationin Section L

Note

Wlren Cbsrlgtnctn@ect@n probe% reca33brsteS@ currentiostrumerrc

8-232

f. Insfrectkon: Using appropriate boltfrde probe, scaninside the holes from the accessible sides of longi-tuchnal beams as illustrated, A sharp meter dcflec-Uq 6s noted durmrg &Jibrdim udng calibrationstandard in accordsrnce with Ssctmn I, till indicate aprobable crack redtating from the hole.

g. Mark end report hrdtcsted defects. See Section Ifor approved temporary marking mstesisls.

h To confirm defect ccmdition6j proceed wttb Back-up NM Proce&re. 3f no defect 18 N@eOtM! proceedto System Securing paragraph

6-364. BACKUP NDI PROCEDURE - FLUORESCENTPENETRANT. Perform fluorescent penetrsnt tnepec-tfon of ewpwted defective areas 6s mqukred.

a. NDI squtpmmfi

(1) Fluorescent persetnntsnsteriakssrdaqutfsm.ertselected from approved list in table 1-ILL

b. Preparation of airplane: Eeme AS for PrtmeryNDI procedure.

c. Accese: Same ae forPrimary NDI Procedure.

d. Preparation 01 parti Remove forward ramp hinges,one at a ttme, and attachment barrel nuts end ac-tuator sturt (2 plsces) in accordance withT.O. 1C-5A-2-12, Section 33. Remove strut and ac-tuator attachment fitting per T.O. 1C- 5A- 3, Section IV.See T.O. 1C-5A-23, Section V, for finish removal.(re-ataratirrn instructions, Strip fhush from local suS-peeted rlefecttre areas. Clean Iod issepecucn are**S8 required in accordance with T,O. 1C-5A-23, 6ec-Uon V.

e. Instrument setUnga/calibration: Not appli cable.

L

Noes

2f a eoapected crack is believed to orighweat a fastener hole, remove the faetener (eddycurrent kcdt hole trispectkon may be used) andstrip and clean surface undsr fammer prkorto penetrant trrepectkm.

bSSPSCtiCSKIospect only the auspectsd Oelectavearose. Perform fluoremmrrt pmetrant inspection maccordance wfth table l-~ Section L and mstructaonscmrtetnad m T.O. 33T&l.1.

g. Mark end report indicated defects. Sea Section 1for approvedtemporarymarking matsrkala.

6-385. STSTZM SECU3UNG Clean areas irrspectecJrestore finishes, reiasta31 removed cmtrponente endperform Operetismaf CheckmW, aerequtr+inac-COrdance with applicable T.O. ‘a.

Figure 7. Example of Format and Content of Eddy CurrentInspection Procedures. (Sheet 1 of 3)

25


MILM-38780A (U~AF)

T.O. IC.5A-36

I

Ml70.0

~E BOLTHOLEPRO*3/a TO1/2INCH10”

LT HOI m4c

fTvPICAfi PLACEs)

Fiour. 6.7)-4/2 Forwo,dRomp Extension Lonsitudinol Boom and All Hiw. F;~n@AtIoch Points ond AcW@or Attwh Points (Shoot 2 01 2)

6-234

Figure 7.~mp”~e of Fe-at and Content of Eddy Current

Inspection Procedures.(Sheet 3 of 3)

26


:’-)

i’

i-’]

KIL-M-38780A (UaAu~

T.O.K-5A-36

6-2s3

-e 7. BramPle of Format and Content of Eddy Cu2!reniInspection Procedures. (Sheet 2 of 3)

. . )27’


MILM-38780A (ubAF)

7.0. IC.5A-36

6-852. MAIN LAh~ING GEAR FLOOR BEAM TRUN-NION LUG,DRAWINGS 4F23031, 4F23032,4F’23033 AND 4F23034.

6-853. DILsCRIPTION. (See f!gure 6- 158-5/2. ) Ths:wun lmduII? @?ar f300r trmms arc lncstod tn thercnfcr fueclaxc at Fuselage Sra@ms 1303, 1383,]5~3, ~~ ]603. E@, Of ~ f~r floor hams hag

le[[- and right-side load carrying trunnion lugs atthe beam enos in the area of tbe main landing gcsrshnck strid aassmbly attMtmwant to tits floor beam‘t runmona. Two bushed halos in ths trumion lugsprovide aetxchmam :or mmn iaodcog war lrumughracrs. The heiams are machmod from 7075-T6alummum forgings, shnt peened, sulfuric acidarmcksed, and painted with wash primer, e&mKypolyamde pmmer, and two coat Of abraamm-re-anexantpolyurethane.

6-854. DEFECTS, Two machmed, Imahsd, 1/2-Inchdvmete r hoies m ●ach trunnion IW result inmate ma] and grain rumntt, and nrterie rence bushtnminstalled m these holes Impose auatamed surfacetensile stresses on the part. Cracks may originate

arid propagate radis3ty from the txcakd holes in eaehtnmnmn lug.

6-855. PRIMARY NDl PROCEDURE - ULT34ASCINIC.

a. NDI eqtnpment

[1) Rctlectoscope, Spsrry UM-715 or ecpuvalent.

(2) Transducer, 5.0 mflz, O.187-inch, Long\-tudirud Wave, Sperry PIN57A2284,oreqwvemm

(3)Cable,6-ionc,M~crodot/UHFCrnnector,SperryPIN57A2Z70i0reqmvalent.

{4)VideoPlug-In Modcsh, 10N, Sperry P/N50E 533 or ecpiivalent.

(5) Couplant, L@ Oil.

(6) Calibration Standard and Guide, as ilhls-trated in fiaure 6- 1S8-S/2.

b. Preparstioo cd atrpkae: No special preparatimreqmred.

c. Acmes: Inspection areas are accessible wtth themain landing gear down and locked, and outboardmmn landing gear doors OPSn.

Nom

Do not remove bushmga from holes m thetnmldon M.

d. %eparatmn of part: Remove two plates, p/N4~5926, at Fuadage Stawms 1303 and 1603, andtwo plates, P/N 4F75925, at Fuseiage Seatma 1363

omd 1523 from each trunnim iug m sccordmcs vIthT.O. lC-5A-2-2, ssct~on U. Rsm- oniy two plates

at a tms at any one of the four trunnion lugs perstale of airplane. See T.O. IC-5A-23, &ctirsi V, forc~eacrmgmmructibos.Cleankai inapectmn areas asnecessary to permit Ifocd contact betwsen part andtransducer gutde.

e. Instrument settings/cs3ibration:

(1) Apply Cnupmt to the calibration standard aur-fms that M opposite the sew sttt. Couple the trans-ducer goide to ths calibration standard by insemtngthe pin Portion of the guideinto the troshed hole m thecallbramn stasuiard. Me rt longitudinal wave t mm -duesr utto guide hole marked either %W” or ‘{CCW. ”ltcfer to Section 1, Initial Shear Wave Calibration -Solid S@ndard with Cmtour’sd wedge.

(2) Ad}@” traoSdueSr/@idS to positron No. 1.CS3ib-te the tnatrument to diapiay the first ioterfaeawise near the iaft side of the CRT.

(3) FtOtatetrSMdUCer/tWids in a cloetnsise di-rection to Prmtion No. 2 and ncke display of saw cutsignal m CRT.

(4) Mju@ sweep to d~sptay the eaw cut signalnear the right mde 03 the CRT.

(5) Msmmiss the stsnal from tbs saw cut by ad-jucrtmg the t ranaducer/guide PcOitlco. Mjust saw cuts- amplttude to 80 percent scow saturatmn.

(6) Scan mspectmn surface and observe signalfrom saw cut. This calibration mmulates a crack mths resin iawiuu tear Cc+r ‘Zca=. :PS.4=. !>%ho]?radms surface that is commm to the txt.shingoutsl~dlamster surface.

f. fnspecuon: hrspct eight (law each SUM of air-plane} mam lsndmg gear floor beam trunnim lugs (twoholes per big) m UN hoie radua area as illustratedand m accordance wtth tire followms:

(1) Apply coophnt to ths trumdon he in lbs areaof the bcmbsdhole that IS to bs covered by the gwdc.lnse rt ]MSitUdlN] wave trMSCJUCerlntO tha gwdchcde marked 44CW” and coople t rsnaduecr/grnde tothe trurmim lUC. insert the guide pm mto ths lWbushed hoio.

(2) Scan the lug in a ciockwiae dmection.

(3) Remove the Iongltudmsl wav~ transducer fromthe guide hole markad “CW’} end insert into tim guidehde marked “CCW.” Scan tbs lug m a coonterclmk-WWCdirectmm

(4) Repeat stew (1) thrmsgh (3) for the e4har holein the tnmmcm lug.

(5) tipeat steps (I) U=@ (4) to Km - ~mstwo botes from * *r side of tbe hsg.

6-S9S

Figure 8. Example of Format and Content of Ultrasonicinspection Procedures. (Sheet 1 of 6)

28


II

-.I )

MILM-as780.4 (IJwlF)

T.O. lC-SA.Jb

1’

I

--

I)

(6) ACRTsigosl similar totllcwd@ayedforthe saw cut in the calibmtton procedure will Indicatea probable crack in the truunmu iug hCI~erad,us SUr.

kit that ia Wmmm to the bushing musxfe diametersurface.

g. Mark and report indicated defects. Sce Section Ifor approved temporary markmg materials.

h. To cmsfl?m deieet condatwma, proceed wtth Back.up NDI Pmcedura. If 00 defect is sctapcted, proceedto System Securing.

6-856. BACKUP MM PROCEDURE - FLUORESCENTPEA’ETRANT. Perform fluorescent penetmnt m-spectmn of wspected cMsctive areas u required.

a. NDIe@pnmnt:

(1) Pluorescem penetranl materials and equipment SeAactedIrom approved list m tablt 1.111.

b. PrciMrStlm cd amplsna: No epecial preparationre+md.

c. Access. lnsfsectmnareasare accessible With themam lasutmg gaar down and locked, and main lardinggear doors open.

d. Preparation of part: With the plates removed fromtlw trunnion lUE, remove the bushing from the ●a-pected defectwc hole If required, Refer to T.O. lC-5A-3, SectionI, [or in.structmn... See T.O. IC-SA-33,

Scctim V, for funsh removal/matontim m CIWII.mg ioetructiona. Strip fu-uah from heal suspecteddefective amaa. Clean inaprcticm areas as requiradto psrform fluoreaccnt prnetrant Inspection (eddycurrent bolt hole inspection may be used).

a, leetntment eetttngs/oallbratirn Nfi4a~mbia,

f. Inapctlm: Inspect only the aupected defecttvaamaa. Perform fluorescent pmetrant inspection inaccordance with tabIe 1-1, *ction 1, and iastsuctimacatamed in T.O. 33B-1-1.

g. Mark and report indicateddefects. See Sectm Ifor approved temporary marking materials.

6-857. SYSMM SECURfNO. Clean arms mepected,restore fimshes, reinstall mmowed com~ts, andperfam ~rwimal checkouts, as mquimd, in ac-cordawe with q)lkabi, T.O. ‘s.

... )

6-s06

Figure “8. Example of Format and Content of UltrasonicZn@pection Prooedwes. (Sheet 2 of 6)

29


MILM-36’760A (TWF)

7.0. K-5A*M

II

(?#’

4$

w- 8“ Example of Fo~t and Cmtent of Ultr*~icInopeotlw Procedures. (Sheet 3 Of 6)

lwlcAL4-

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~tiih>

MG RO@ WTUINNION

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o

~ “ ‘

LUG

H

P LONGITUDlt’4AL WAVE TSA~=AND TmN-m GU1OE - WllHTRANSOt=k IN GUIOEMOLEMM-‘CW, SCANMOUND LUG IOUCLOCKWSE. WTH TUANSOL$CER INGUlOE HOLE MARKED‘CCW, -NAKUJNO LUG liCWECOLINfEU~WK-WWIE. M3NTVtO*--~

:=~&=WK

STEEL MSH!NGoaENTAn@J m

(tY? 2 MOLES)II

I

I

30


‘- ‘)

MIL-M-38780A (Usm)

T.O. lC-SA-3b

\. \\\\

I

i’

,\

I

,LONGITUDINAL WAVE TRANSWCER

d~v~w,= AND TRANSD~ER GUIDE - WITH

\

TRANSDUCER IN GUIDE HOLE MARKED‘CW,’, SCAN AQCUND LUG HOLECLOCKWISE. WITH TRANSDUCER INGUIDE HOLf MARKED “CCW”, SCANAROUND LUO HOLE COUNTER-CLOCKWISE.SCAN TWO HOLES EACH SIDE OF W.

\

m

\\\ ~ %%;::%,

\\\ L&l —f?JOBMLL .RACK

-i ~cl.24 (TvP2 FWXS)

4$figwo 4- 158-S/2.

6-s06

Figure 8.. .JlxanpleofInspection

ANGLE WEDGEwusnc MIL-P-21 105)

~1413,*

Main LOndhg Gmr floor &am 7nmai.n kg

(Shod 2 of 4)

Format and Content of UltramnicProcedures. (Sheet 4 of’6)

)31


MIL-M.38780A (U=m)

j!m’”PLAIN Bu5HINGTO BE FLUSH

cALiBf@Tl~ SIANM~(7w5-M ALUMINUMOR EQUIVALFNl_) n,1,, T

,1.0,,t,

Figw. 6- 1S$-S/2.

Figure 8. Example of~apection

\

CALIMATl~ STANOA~ ANDTMN50UCEX GUIOEw ~o~ 3-3

Main bnding Cow Ftou ~ Vw- MI

(Sbnt 3 ~ 4 a-sw

Format and Content of UltrasonicProoe@res. (Sheet 5 of 6)

32


MILM-3s780A @MF)

.0. IC-SA-36

I

I

1I

I

POSITIONNO. 2 ~$lTION No. I

CRT RESEN?ATION SHOW?4 IS W?ICALFOR TRANSDIXER IN EITHER GUIDEHOLE MARKED %W” AND ‘CCWO.

TYPICALCRl MSSENTATIW

Pigum 4.1S8.5/2. Moin landing Coot FSOWkm Twnnion ho

ISh.wt 4 0{ 4)

9-S-W1434

.-m

Wwe 8. Exemple of Format and Content of UltrasonicInspection Procedures. (Sheet 6 of 6)

. . ) 33


lNSTRIJCll@S: in ● a@iouhg ●ffort to nmka our ~ dosumentebetter,tbe DoDprcAdes thbfocmforueein

submittingeommsntssnd qgestiooe for improvements.AU were ofmilituyetmnddktion documeob amiantdtopnmide

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aekaowbdsementwillbermdkl toyouWitllioSo d8Ystoletyou know tit yourCommeob mmrecaidMduebeiog

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epecificdioo~@ = ~-t -t--. CknmmentamItmWed ortthieformdo notcoaetituteorimply•utbo~tioa

towmi= my porthmofthereferenceddocument ortoameod conbactualmquhoenta.

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(Fold ,tOng th& JhM)

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(Fold don# thb line)

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DEPARTMENT OF THE AIR FORCE

111111 ~]

UNITED STATES

OFFICIAL BUSINESS

‘ENALT~ FOR PRIVATE U$E~ I BUSINESS REPLY MAIL II FIRST CLASS ?EFtM!T NO. 732% WASHINGTON O. C. IL J

POSTAGE WILL BE PAlO BY THE DEPARTh4ENT OF THE AIR FORCE

AFLC (MMOKP)WRIGHT-PATTERSON AFB , OH 45433


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STANDARDIZATION DOCUMENTIMPROVEMENT PROPOSAL(Se itwnwckm - Rfvast Sids)

, DOCUMENT N’UM8En 2. DOCUMENT TITLE

1L NAME OF 8UDMlTTlMt? ORGANIZA?1ON 4. TVFE OF ORGANIZATION {Hd w)

c1VEUOOR

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●ROELEM AREAS

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c. ~mdobulo tolRmOmmMd=tbm:

. REMARKS

a NAME OF WBMITTE~ /i.at, Fht, Ml) - Optialti b. WORK TE Lli?MONE NUM5E- /IwAM4 ArnC+) - O@iO@@

. MAILING ADORE= f5kc CW, .9*w, Zl? Cod@) - OmtonmI S. OA7E OF BUSMI=IW W’MMDD)

IDII :OZ. 1426 PRC VIOUS EDITION IS ~01.ETE.


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