Non-Destructive Testing (NDT) techniques used in aircraft maintenance,

including a list, a short explanation of each procedure, and the materials &
equipment used:

✅ List of NDT Techniques Used in Aircraft Maintenance:

1. Visual Inspection (VI)

2. Dye Penetrant Testing (DPT or PT)
3. Magnetic Particle Testing (MPT or MT)
4. Ultrasonic Testing (UT)
5. Radiographic Testing (RT)
6. Eddy Current Testing (ECT)
7. Thermographic (Infrared) Testing
8. Acoustic Emission Testing
9. Tap Testing (for composites)

🔧 1. Visual Inspection (VI)

🔹 Procedure:

1. Clean the inspection area.

2. Use direct or remote viewing tools.
3. Visually check for cracks, corrosion, leaks, dents, or loose components.
4. Document findings.

🧰 Materials & Equipment:

 Inspection mirror
 Magnifying glass
 Borescope or videoscope
 Flashlight or headlamp
 Surface cleaner
🔧 2. Dye Penetrant Testing (DPT or PT)

🔹 Procedure:

1. Clean the surface.

2. Apply penetrant and let it dwell (5–30 min).
3. Remove excess penetrant with cleaner.
4. Apply developer to draw out penetrant from flaws.
5. Inspect under white light or UV light.
6. Clean the surface after inspection.

🧰 Materials & Equipment:

 Dye penetrant (visible or fluorescent)

 Developer
 Cleaner/remover
 UV light (for fluorescent penetrants)
 Lint-free cloths

🔧 3. Magnetic Particle Testing (MPT or MT)

🔹 Procedure:

1. Clean the ferromagnetic surface.

2. Magnetize the area (using AC/DC yoke or coil).
3. Apply dry or wet magnetic particles.
4. Look for particle buildup indicating defects.
5. Demagnetize and clean the part.

🧰 Materials & Equipment:

 Magnetic yoke or coil

 Magnetic particles (dry or wet fluorescent)
 UV or white light
 Demagnetizer
 Cleaner
🔧 4. Ultrasonic Testing (UT)

🔹 Procedure:

1. Apply couplant to surface.

2. Place transducer on the surface.
3. Send ultrasonic waves and observe reflected signals.
4. Interpret data using oscilloscope or digital display.

🧰 Materials & Equipment:

 Ultrasonic flaw detector

 Transducer/probe
 Couplant gel (e.g., glycerin)
 Calibration blocks

🔧 5. Radiographic Testing (RT)

🔹 Procedure:

1. Place X-ray/gamma ray source and film (or detector) on opposite sides of
part.
2. Expose the part to radiation.
3. Develop the film or view digital radiograph.
4. Analyze for internal flaws.

🧰 Materials & Equipment:

 X-ray or gamma ray source

 Film or digital detector
 Film processing chemicals (for film radiography)
 Protective gear (lead apron, dosimeter)
🔧 6. Eddy Current Testing (ECT)

🔹 Procedure:

1. Select proper probe and calibrate instrument.

2. Scan the probe over the conductive surface.
3. Observe signal changes indicating flaws or material changes.

🧰 Materials & Equipment:

 Eddy current flaw detector

 Eddy current probe (surface or bolt hole)
 Calibration standard
 Surface cleaner

🔧 7. Thermographic Testing (Infrared Testing)

🔹 Procedure:

1. Heat the part (externally or through internal heat sources).

2. Use IR camera to capture temperature distribution.
3. Analyze thermal anomalies indicating defects like delaminations or
moisture.

🧰 Materials & Equipment:

 Infrared (IR) thermal camera

 Heat source (lamps, hot air gun)
 Computer software for analysis

🔧 8. Acoustic Emission Testing

🔹 Procedure:

1. Attach acoustic sensors to structure.

 2. Apply stress (load or pressure).
3. Record and analyze sound emissions from crack initiation or growth.

🧰 Materials & Equipment:

 Acoustic emission sensors

 Data acquisition system
 Load application setup (if applicable)

🔧 9. Tap Testing (Primarily for Composites)

🔹 Procedure:

1. Tap the composite surface with a coin or hammer.

2. Listen for sound variation (dull sounds may indicate delamination or voids).

🧰 Materials & Equipment:

 Coin, tap hammer, or electronic tap tester

 Trained ear or acoustic sensor

📝 Summary Table

Material
NDT Method Key Use Main Equipment
Compatibility
Visual Torch, mirror,
General surface defects All materials
Inspection borescope
Non-porous Penetrant,
Dye Penetrant Surface cracks
materials developer, UV lamp
Magnetic Surface/subsurface Ferromagnetic Magnetic yoke,
Particle flaws only particles
Metals, Flaw detector,
Ultrasonic Internal flaws
composites probe
 Material
NDT Method Key Use Main Equipment
Compatibility
Metals, X-ray/gamma
Radiographic Internal defects
composites source, film
Conductive
Eddy Current Surface/subsurface Probe, EC meter
materials
Delaminations, water
Thermographic Composites IR camera
ingress
Acoustic Crack growth Metals, Sensors, stress
Emission monitoring composites setup
Tap Testing Delaminations Composites Tap hammer or coin

Here are examples of part numbers for common equipment and materials used in
aircraft NDT techniques:

🧰 Dye Penetrant Testing (DPT / PT)

Solvent-Removable Visible Dye:

 Magnaflux SKL-SP1: 1 L — F01001, Aerosol — F01002 ([Link])

 Magnaflux SKL-SP2: Aerosol can (case of 12) — 01-5155-78; 1 gallon —
01-5155-35; 5 gal — 01-5155-40 ([Link])
 Alternative listing: Magnaflux SKL-SP2 Bullseye code 01-5155-83 aerosol
400 mL (Boeing distribution NSN code)

Water-Washable Visible Dye:

 Magnaflux SKL-WP2: Aerosol (case of 12) — 01-5190-78; 1 gal —

01-5190-35; 5 gal — 01-5190-40 ([Link])

Accessories:

 Tam Crack Comparator — D03026

 Aluminium Test Block — D03015
 Ni-Cr Test Panels (pair, 50 µm) — 506254
  TAM Panel / Z5 — D03014 ([Link])

🛠️ Magnetic Particle Testing (MPT / MT)

While specific part numbers vary by magnetizing equipment, typical OEMs (e.g.,
Magnaflux, GE) supply yokes such as:

 Magnaflux Y-2 Magnetic Yoke – check with supplier for updated codes
 Magnaflux Y-1 Portable Yoke
 Fluorescent magnetic particle powders (e.g., Zyglo ZP-4A) often don’t have
public part numbers but are listed on QPL for AMS compliance.

(Recommend referring to supplier catalogs as these are often updated.)

🧰🔬 Ultrasonic Testing (UT)

Probes / Transducers (by Olympus, GE, Sonatest):

 Olympus 5 MHz, 1” Dual Element – e.g. 34-271-ST5

 Phased Array UT Probe – model-specific part numbers per vendor

Calibration Blocks:

 Steel block, 2 MHz flat bottom hole – commonly TC-1 or TC-1A

 Aluminum block, 5 MHz – e.g. AC-1

(Exact part numbers depend on manufacturer; verify with vendor catalogs.)

🔦 Radiographic Testing (RT)

 X-ray generator tubes and image intensifier panels have specific model
numbers (e.g., GE MXR-650), but these are highly system-specific and
regulated.
⚡ Eddy Current Testing (ECT)

 Olympus Mantis Eddy Current Instrument

 Olympus IOE-1324 surface probe (5 mm coil)
 Bolt-hole probes: part numbers vary, e.g. IOE-1325

🌡️ Infrared Thermography (IRT)

 FLIR T540/RF Thermal Camera

 FLIR P660 for high-temp composites inspection

🎧 Acoustic Emission Testing

 Physical Acoustics R15α sensor

 Mistras PCI-2 AE data logger

🧰 Tap Testing (Composites)

 Precision Tap Hammer model B&K 8202

 Electronic acoustic tap tester like SKF GTP-10

Yes, in aircraft maintenance, additional instruments and tools are used to verify
the serviceability and calibration of NDT equipment. These secondary tools
ensure that NDT instruments are functioning correctly, producing accurate
readings, and meeting regulatory standards.

Below is a list of key instruments used to check the serviceability of NDT

equipment, organized by NDT method:

✅ 1. General Tools for All NDT Methods

 Instrument Purpose
Used to verify accuracy and sensitivity of
Calibration Standards/Blocks ultrasonic, eddy current, and radiographic
equipment.
Ensures correct dwell times during dye
Timer / Stopwatch
penetrant testing.
Light Meter (Lux/Foot-Candle Confirms proper lighting levels during visual
Meter) and fluorescent inspections.
Measures intensity of UV light used in
UV-A Radiometer
fluorescent PT and MT methods.
Magnetic Field Indicator (Pie Verifies adequacy of magnetization in
Gauge or Hall Effect Meter) magnetic particle inspection.
Used during thermography and PT to confirm
Thermometer / Thermocouple
proper temperature conditions.

🔍 2. Visual Inspection (VI)

Instruments:

 Borescope/Video Scope Test Box – checks light intensity, focus, and clarity.
 Magnifier Test Ruler – confirms magnification and resolution.
 Light Intensity Meter – ensures a minimum of 1000 lux for white light
inspection.

🧰 3. Dye Penetrant Testing (PT)

Instruments:

 TAM Panel / NiCr Test Panel – checks sensitivity of dye penetrant system.
 UV-A Radiometer – verifies UV intensity (for fluorescent dye).
 Surface Roughness Comparator – ensures surface condition is acceptable.

🧰 4. Magnetic Particle Testing (MT)

Instruments:

 Pie Gauge / QQI (Quantitative Quality Indicator) – placed on the surface to

check magnetic field strength and particle visibility.
 Hall Effect Gaussmeter – measures strength of magnetic field (in Gauss).
 Shunt or Magnetic Field Comparator Strip – confirms proper magnetization
level.

🔊 5. Ultrasonic Testing (UT)

Instruments:

 Calibration Blocks: e.g., IIW Block, Step Block, Distance-Amplitude

Correction (DAC) Block.
 Couplant Test Gauge – checks consistency of couplant.
 Pulser/Receiver Checker – checks the UT unit’s signal strength and probe
connection.
 Digital Oscilloscope – used for advanced signal analysis.

🌈 6. Radiographic Testing (RT)

Instruments:

 Step Wedge Penetrameter (IQI) – checks radiographic sensitivity and image

quality.
 Densitometer – measures optical density of developed films.
 Timer & Dosimeter – verifies exposure time and radiation dose.
 Geiger Counter – checks for residual radiation and safety compliance.

⚡ 7. Eddy Current Testing (ECT)

Instruments:
  Calibration Standards: Conductivity standards (e.g., aluminum, titanium
blocks with known flaws or hole sizes).
 Lift-Off Gauges – confirm probe sensitivity to distance.
 Signal Reference Standards – simulate known flaws for comparison.
 Multimeter – checks continuity and coil resistance in probes.

🌡️ 8. Thermographic Inspection

Instruments:

 Blackbody Calibrator – validates infrared camera’s temperature accuracy.

 Reference Heat Source / Calibration Plate – confirms contrast sensitivity.
 Emissivity Tape – ensures consistent surface emissivity for accurate
readings.

🎧 9. Acoustic Emission Testing

Instruments:

 Pencil Break Tester – simulates crack growth to check sensor response.

 Sensor Calibrator (Pulser) – verifies sensitivity and frequency response.
 Couplant Meter – checks acoustic coupling effectiveness.

🔧 Other Serviceability Aids

 Multimeter – checks voltage, resistance, and continuity in all electrical NDT

devices.
 Battery Load Tester – checks battery health in portable units.
 Environmental Monitors – for checking ambient humidity, temperature, or
cleanliness (especially in clean-room NDT).
🧰 Summary Table

NDT Method Serviceability Instrument

Visual Light meter, magnifier checker
Dye Penetrant TAM panel, UV radiometer, stopwatch
Magnetic Particle Pie gauge, Hall effect meter, QQI
Ultrasonic IIW block, DAC block, oscilloscope
Radiographic IQI (penetrameter), densitometer, dosimeter
Eddy Current Conductivity standards, lift-off gauge
Thermography Blackbody calibrator, emissivity tape
Acoustic Emission Pencil break tester, AE pulser

In aircraft maintenance and other industrial applications, NDT personnel are

certified to different levels of expertise and responsibility. These levels are
defined in accordance with international standards like:

 ASNT SNT-TC-1A (American Society for Nondestructive Testing)

 EN 4179 (European aerospace standard)
 NAS 410 (aerospace-specific)
 IS 13805 / ISO 9712 (India/international general NDT)

Here’s a breakdown of Level 2, Level 3, and Responsible Level 3 in NDT:

🧰 NDT Level 2

✅ Role:

 Intermediate-level technician
 Qualified to perform NDT and interpret results

🎓 Qualifications:

 Must have completed training and practical experience (as per standard
requirements)
 Passed both general and specific exams for the method
🛠️ Responsibilities:

 Set up and calibrate equipment

 Conduct NDT inspections
 Interpret and evaluate test results
 Apply NDT procedures and standards
 Train and supervise Level 1 personnel
 Report test results

✈️ In aircraft maintenance:

 Typically involved in routine inspections and defect detection

 May be authorized to sign off inspection results

🧰 NDT Level 3

✅ Role:

 Expert-level personnel
 Highly qualified in one or more NDT methods

🎓 Qualifications:

 Extensive training and experience

 Passed comprehensive exams including:
o Basic
o Method-specific
o Practical (where applicable)
 May hold multiple certifications

🛠️ Responsibilities:

 Develop and validate NDT procedures

 Interpret codes, standards, and specifications
 Provide technical direction to Level 1 and 2 personnel
 Conduct audits and reviews of NDT programs
 Approve techniques and equipment
  Evaluate test results in complex cases

✈️ In aircraft maintenance:

 Often responsible for high-level decisions like defect accept/reject criteria

 May interact with regulatory authorities or aircraft OEMs

👔 Responsible Level 3 (R-Level 3)

✅ Role:

 Highest NDT authority in an organization

 Often mandated by standards like EN 4179, NAS 410, or IS 13805

📋 Responsibilities:

 Responsible for the company’s entire NDT program

 Approves and signs all NDT procedures and techniques
 Maintains training and certification program
 Certifies Level 1, 2, and Level 3 personnel
 Liaison with regulatory bodies (e.g., DGCA, FAA, EASA)
 Ensures compliance with quality assurance and aerospace standards
 Participates in internal/external audits

🧰 Must:

 Be certified as Level 3 in at least one method

 Be designated by management in writing
 Have full authority over technical NDT matters

✈️ In Aircraft Maintenance:

 Acts as the go-to person for resolving critical NDT issues

 May be the final authority on whether a component can be returned to
service
🧰 Summary Table

Level Title Main Role Key Responsibilities

Perform & Inspect, evaluate, supervise
Level 2 Technician
interpret tests L1
Develop procedures,
Level 3 Expert Technical authority
oversee L1/L2
Responsible NDT Program Organizational Oversee entire NDT system,
Level 3 Manager authority certify others

✅ Standards That Define These Levels:

 ASNT SNT-TC-1A
 EN 4179 (required for aerospace sector)
 NAS 410
 ISO 9712
 IS 13805 (Indian equivalent of ISO 9712)