simmer b787 readiness presentation 17.10
TRANSCRIPT
B787READINESS
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INTRODUCTION
Thisweekmarkstheintroduc=onoftheB787-9totheQANTASfleet
Thereisgreatexcitementandexpecta=onwithinourorganisa=onfortheaircraFanditspoten=altodeliverimprovedcomfort,performanceandsafetyforthecustomer.
WhatdoesthismeanforEngineering?Specifically,whatdoesitmeanforNDT?
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The Journey
InJanuary2003,BoeingannouncedtheB787asthereplacementproductforitscancelledSonicCruiserprogram.
ThiswasdrivenbytheairlinesshiFisopera=onstrategyfrom“hubandspoke”routesto“pointtopoint”routes.
AFernumerousproduc=onandflighttestdelays,thefirstaircraFwasdeliveredtoANAinSeptember2011
TheB787-8enteredservicewithJetstarinOctober2013.
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What is a B787?
TheBoeing787usesmorecompositematerialsinitsairframeandprimarystructurethananypreviousBoeingcommercialairplane.Approximately53%
Becauseoftheextensiveuseofcomposites,itisimportanttounderstandtermsandconceptsaboutcompositematerials.
Inaddi=ontomorecompositematerials,thegeometryofthe787structureisdifferentfrompreviousBoeingmodels.
Itisalsoimportanttounderstandthedifferencesbetweendamageevalua=onformetallicstructurescomparedtodamageevalua=onofcompositestructure.
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Material ApplicaAons
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Material SpecificaAon
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Challenges
IntheworldofSpecialistMaintenance,NDTinspectorsareauthorisedtoperformaprocess.Thereisnotypera=ngforNDTinspectors.
Infact,yourNDTinspectorisalreadyauthorisedtoperformthatprocessontheaircraFthathasn’tbeenbuiltyet!
However,inthePart145MOS,theAMOisrequiredtoensurethatacer=fyingemployeehasan“adequateunderstanding”oftheaircraForaeronau=calproduct.
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What do we need to do for our inspectors?
1) Safety.2) Structuralawareness.3) Documenta=on.
4) Applica=ons.
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Safety
WeneededtogenerateasafetyawarenesstrainingpackageforanyoneworkingontheaircraF.
TheB787usesmanynewelectro-mechanicalsystemsnotseenonpreviousfleets.
Employee’sneedtorecognisedangersandbealerttopoten=alhazards.
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Structural Awareness
QantasdevelopedastructuralawarenesstrainingpackageforallemployeesincontactwiththeaircraF.
TheNDTinspectoralsoneedstocompetentlynavigatetheSRM.
NotallB787’sareconstructedthesame.
TherearesignificantdifferencesbetweentheB787-8andB787-9.EachhavethereownSRM.
Theinspectorneedstobeawareofthemanufacturingtermsandtechniquesofthematerialsused.
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Structural Awareness
Fromtherela=velysimplestructures
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Structural Awareness
Tothemorecomplex
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Structural Awareness
AddStringers
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Structural Awareness
Andframes
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DocumentaAon
TheSRM(andAMM)usenewDataModuleCode(DMC)forS1000DdeliveryintoMaintenancePerformanceToolbox.
DeliveryofS1000DdataintoToolboxusesaStandardNumberingSystem(SNS)applyingaDataModuleCodes(DMC's)toeachSRMProcedure.EachDMChasmul=pleDisassemblyCodeswithinanATA(beginningat00Aandcon=nuingwith01A,02A,03Aandsoon)alongwithanInfoCodethatiden=fiesthetypeofSRMData.
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ApplicaAons
BoeingproducefortheAirlines,atoolingandequipmentmasterlistforEntryintoService
TheonlyNDTtoollistedinthemasterlististheGEnxFanBladeUltrasonicInspec=onKit–forpostbirdstrikefanbladeinspec=on
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ApplicaAons
AirplanehitbygroundequipmentFuselageBirdStrikeFuselageLightningStrikeFanBladeLightningstrikeFanBladeLeadingEdgerepairFuselageBondedrepairInspec=onWingLowersurfaceposttyreshredB787-9HorizontalandVer=calStabiliserLeadingEdgeskinsfors=ffenerdisbondB787-8HorizontalStabiliserLeadingEdgeforskintocoredelamina=onB787-9HorizontalStabiliserleadingedgeHybridLaminarFlowControl(HLFC)forskintocoredelamina=onVer=calStabiliserleadingedgeskintocoredelamina=onWingLeadingedgeheatedandunheatedslats
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ApplicaAons
Damagedetec=oninBMS8-276material
BoeingNDTmanualallowstwomethods:
GuidedAscanat4mmincrements
TCG
Timeconsuming
Nopostinspec=onanalysis
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ApplicaAons
RecommendedistheUltrasonicLineararray(PAUT)withatwodimensionalencodersystem
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ApplicaAons
BondedRepairInspec=on
Cscanmethodisrecommendedwhereaccessandsurfacecondi=onsaresa=sfactory.
Providessignificantpostinspec=onanalysis
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ApplicaAons
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Bondlineflaws
ApplicaAons
PorosityCalcula=ons
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ApplicaAons
B787-9
HorizontalStabiliser
LeadingEdgeskin(Hybrid)LaminarFlowControl(HFLC)
EmploysanominatedBondtester(resonancemode)
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ApplicaAons
Ver=calStabiliserLeadingedgeskintocore
EmploysaBondtesterinthepitch/catchmodebutisonlyapplicableiftheAluminiumerosionshieldisbondedtotheGRFP
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ApplicaAons
GEnxFanBladeInspec=onpostBirdStrike
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ApplicaAons
RampDamageChecker
TheproceduretousetheRDCiscontainedintheSRM(nottheNDTmanual)
Therearelimita=onswheretheRDCisused
Onlylaminatedstructures
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ApplicaAons
RampDamageChecker
ThisisabasicUltrasonicInstrumentcalibratedontheaircraFstructure.
Itdisplays“Good”or“Bad”andwillneedtoberecalibratedforeachthicknesstobeinspected
ItisdesignedtobeusedbyNonNDTpeople,however,indica=onsshouldbeverifiedbyinstrumentedNDTmethods
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Resources
Thesophis=ca=onoftheaircraFcomparedto“metal”types,andpoten=alrouteopportuni=esalsopresentschallengesonwheretoposi=onresources.
Thehighcostofini=alequipmentsetup,andinspectorfamiliarisa=on/trainingisprohibi=veinasmallfleet.
Consolida=on,resourcepoolingandrecogni=onofotherMRO’s(outsidetheAustralianregula=ons)tosupportthefleetmustallbeconsidered.
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Summary
Toensure“adequateunderstanding”weneedtoconsider,trainanddocument
1) Safety.2) Structuralawareness.3) Documenta=on.
4) Applica=ons.
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Acknowledgements
Boeing787StructuralAwarenesstrainingpackage
AustralianAvia=onmagazine
Boeing787NDTmanual
BoeingB787-9SRM
TheAustralianBusinessTraveller
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