05-50 COMPOSITE FUSELAGE INSPECTION LEVEL 2

The inspection level 2 on the fuselage has to be performed using an ultrasonic

analysis, which gives an immediate and detailed picture of actual condition of an-
alysed structures, mapping dimensions and types of likely anomalies detected.
This method provides information about:
 Delaminations
 Disbondings
 Inclusions
 Voids
 Porosity
 Wrinkles
The acceptance limits for the ultrasonic analysis are divided in three classes listed in
Table 1. The exceedance of at least one of the criteria is cause of unacceptability.
Table 1 also shows: tolerance limits for adhesive thickness measurement;

Table 1: Acceptance limits

Acceptance Classes
Acceptance Criteria
Class 1 Class 2 Class 3
Maximum area, Consist of the maximum area of the rec-
tangle that inscribes the defect (Lmax x Lmin or L2max x
L2min in Figure 1). Belonging to this category all defects
which have a length (L1min or L2min in Figure 1) smaller 100 mm2 225 mm2 400 mm2
than or equal to Lc, so the smallest linear size of non- Lc = 6 mm Lc = 12 mm Lc = 24 mm
M = 16.7 mm M = 18.8 mm M = 16.7 mm
acceptable defect is M. The distance D between edges of x 6 mm x 12 mm x 24 mm
the defects (D in Figure 1), is the minimum distance under D = 10 mm D = 15 mm D = 20 mm

which two defects are considered as only one. For lower

distances of D, the dimensions of unified defects are:
(L1max + D + L2max) x (L1min + L2min).
Minimum distance from trimmed edges. Defects locat-
ed at distance lower of Db from the edge and with the Db = 6 mm Db =12 mm Db = 24 mm
length (L1min or L2min in Figure 1) lower than or equal Lb = 6 mm Lb = 10 mm Lb =10 mm

to Lb are not acceptable.

Minimum distance from holes. Defects located at dis-
tance lower of Df, and with the length (L1min or L2min Df = 4 x Ø Df = 3 x Ø Df = 1 x Ø
in Figure 1) lower than or equal to Lf are not acceptable. Lf = 6 mm Lf = 6 mm Lf = 6 mm
Ø = hole diameter.
Density of defects. For each area Ad, a number of defects Ad = 1 m2 Ad = 1 m2 Not applica-
bigger than N, is not acceptable. N = 10 N = 10 ble

Adhesive thickness measurement 0.2 mm to 1.5 mm

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COMPOSITE FUSELAGE INSPECTION LEVEL 2
 Figure 1: schematic rapresentation of two defects

Acceptance classes for the fuselage shells are defined in the figure 2 and refer to both
shells (left and right).
The Class 2 limits have to be applied for PVC areas (highlighted in red), the measures
shown in figure 2 don’t include the tolerances, therefore use it properly.
The Class 1 limits have to be applied for the laminates area (highlighted in blu),. This
area is identified on the fuselage through the points A (at the end of the fuselage below
the empennage), B (intersection with the prolongation of the tail plane), C (window
end), D (parallel extension of C to cockpit), E and F (both on particulars of the win-
dow); the width is approximatively 350 mm.
The Class 3 limits have to be applied, for the remaining laminates areas (not colored).

Figure 2: Acceptance classes for the fuselage shells (the measures shown in figure 2 don’t
include the tolerances)

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COMPOSITE FUSELAGE INSPECTION LEVEL 2
 The HSPE (hand scanning pulse-echo) method shall be applied using a calibrated in-
strument USM 35X (or equivalent at least in terms of gain, bandwidth, pulse, represen-
tations characteristics) with certified probes TECHNISONC GRD-0502-HR 5.0 MHz,
Ø=0.25", delay line of 8 mm in Perspex (or at least equivalent in terms of size and
range).

Table 2 shows the setup for the instrument, above mentioned:

Setup parameters for HSPE inspection

Coupling Water
Mode PE
Reject 0%
Speed 3000 m/s
Filter 2-20 MHs
Damping Low
Intensity High
Rectification FW
Amplification 36±2 dB (for bonding 50±2 dB)
Pulse repetition rate Auto low
Overlap ½ probe diameter
Table 2

Procedure

Step 1:Perform an inspection on applicable standard coupon, used as reference, placing

a gate between the front and the back-wall echo and another gate around the back wall
echo at a level of 20% screen height; using the setup parameters specified in the follow-
ing, verify positions and sizes of artificial discontinuities using the 6 dB fall method.
Measured sizes of simulated defects shall result equal to the nominal values ±10%.
NOTE: The standardization shall be repeated at least every two working hours, after
substitution of any part of the inspection system and if any malfunction or anomaly is
suspected.

Step 2: Set the instrument previous mentioned according to table 2

Arrange the gain so to obtain a back-wall echo ranged 80% to 90% screen height
Divide the fuselage in areas of maximum 150x150 mm dimensions, taking care that two
consecutive sectors have an overlapping area of at least 10 mm.

Step 3: Before starting the inspection each sector shall be visually inspected in order to
be sure that the surface is dry and free from foreign object, dirt and contamination of
any nature.

Step 4: Divide the flanges and radius areas separately. Each radius area shall be
scanned with at least one scan line.
Connect the probe to instrument and turn it ON.

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COMPOSITE FUSELAGE INSPECTION LEVEL 2
 Slowly and uniformly spray water on the surface to be inspected.
Put the probe (equipped with the delay line) on the area and set on the USM 35x the pa-
rameters in Table 2.
Scan slowly the surface with the probe along parallel lines spaced of maximum 2 mm
apart. Perform scanning with a constant speed (speed should not exceed 10 mm/s) and
continuously observe the A-scan.
NOTE: When a relevant indication is found along a scan line: mark the line performed
up to that point with the pencil or pen; perform an areal scan (at least 12 mm x 12 mm
and examine anyway until the signal of flawed indication appears), with scan speed
halved, along both axes to delimit the size of the indication; if the indication appears on-
ly in a single point of application of the probe, assume a size equal to half probe diame-
ter; mark the contour and the suspected area with the pencil or pen; continue scanning
along the line.

Interpretation criteria: the defects are present if the back-wall echo is degreased of 12
dB compared to the defect free areas of the applicable standard or presence of an inter-
mediate echo (different from the front echo and back-wall echo) with an amplitude
greater than back-wall echo
NOTES:
 Intermediate echoes with high amplitude accompanied by the disappearance of the
back-wall echo can be an indication of delamination or voids.)
 A significant reduction of the back-wall echo not accompanied by the presence of in-
termediate echoes may indicate porosity.
 Intermediate situations may indicate inclusions or voids arranged not perpendicular
to the incident beam.

NOTE: Only specifically qualified personnel can perform the test.

EACH DEFECT FOUND MUST BE REPORTED TO COSTRUZIONI
AERONAUTICHE TECNAM, SEE ATA1

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