Aircraft Structural Integrity – Engineering and NDT Case ... · NDT&CT = Inspections requiring NDT&CT Development 0 USN/RCAF 1 RAAF Gen. 0 NDT&CT 0 USN/RCAF 2 RAAF Gen. 0 NDT&CT

COMMERCIAL IN CONFIDENCE


Callum McGregor – Principal Engineer

Aircraft Structural Integrity – Engineering and NDT Case Studies

25 October 2017




COMMERCIAL IN CONFIDENCE ASI – Engineering and NDT Case Studies | October 2017 | ©

Agenda

1 QinetiQ Overview

2 Defence Regulatory Environment

3 ASI Program

4 Case Study 1 - F-18A/B LOTEX

5 Case Study 2 - PC-9/A ASIP Recovery

6 Case Study 3 - F/A-18A/B Bootstraps Wide Area Inspection

7 Summary

2



•  QinetiQ Australia is a people-based business providing trusted and impartial advice and services across the aerospace, land and maritime domains of the Commonwealth Government of Australia Department of Defence and to Government, training and industry sectors

•  Largely independent of the Defence supply chain and the large product-focused Original Equipment Manufacturers. Impartiality combined with technical know-how.

•  350 people across Australia –  Adelaide –  Melbourne (South Melbourne and DST-FB) –  Canberra –  Sydney –  Brisbane

QinetiQ Australia Overview

ASI – Engineering and NDT Case Studies | October 2017 | © 3



•  20-year history of providing Structural Integrity Solutions to Defence

•  Industry Partner to the Australian Defence Aviation Safety Authority in a tri-Partite arrangement with DST:

•  Strategic alliance with DST Group for Research & Development

•  Delivering services to DASA, DST, Sustainment Organisations, Acquisition Projects and Prime System Integrators


QinetiQ Australia – Structural Integrity

Regulatory Oversight

Scientific Advice Engineering



•  Privileges cover all ADF registered aircraft for: –  Classification of changes and repairs –  Approval of minor repairs –  Approval of minor changes to Type Design

DASR Part 21J Approved Design Organisation


DASR Part 21 – Aircraft Design, Production & Certification

DASR Part M – Continuing

Airworthiness Management DASR Part 145 –

Requirements for Maintenance Organisations



•  ASI – Assures structural strength and stiffness, throughout an aircraft’s service life, when operated within the approved envelope, restrictions and limits

•  ADF adopt the United States (MIL-STD-1530) “Cradle to the Grave” approach to ASI –  Part 1 – Design Information –  Part 2 – Design analysis and Development Testing –  Part 3 – Full Scale Testing –  Part 4 – Certification & In Service Management Data collation –  Part 5 – In Service Management


Aircraft Structural Integrity Program - Overview



PC-9/A

•  ASIP Recovery Project

F-18A/B Bootstraps

•  Wide Area Inspection

F/A-18A/B

•  Structural Life Extension of RAAF F/A-18A/B Hornet


ASI Engineering and NDT Case Studies



Case Study 1 - F-18A/B LOTEX




•  A Life Of Type Extension (as a minimum) needs to consider –  A review of all baseline primary (FC/MC) airframe structure –  A review of critical system and role equipment components –  A review of all repairs and tail specific modifications to baseline primary airframe structure

•  Process for the review of all FC and MC Parts was: –  Review all available new data –  Reassess the basis for SLL or SBI on Primary Airframe Structure –  Extend life limits where easy to do so –  Propose follow up actions where life management cannot be extended

–  LOTEX achievable without further action –  LOTEX achievable with one-off inspection –  LOTEX achievable with recurring SBI program –  LOTEX achievable only with modification or replacement


Case Study 1 - F-18A/B LOTEX - Approach


COMMERCIAL IN CONFIDENCE ASI – Engineering and NDT Case Studies | October 2017 | © 10

Case Study 1 - F-18A/B LOTEX - Approach

Develop Review Task Proposal for

Major Structural Assembly

Steering Group Committee (SGC)

Consisting of experienced leaders from:

DSTO ASI-DGTA

QinetiQ

Approved Approach

LOTA Initial Scope

Discuss Debate

Agree Advise

More Work Required Actions Decisions

TFSPO Input & Feedback

Working Group Meeting Format



Case Study 1 - F-18A/B LOTEX Inspection Summary

USN/RCAF = Inspections sourced from USN HFH or RCAF ALEX inspections RAAF Gen = Inspections sourced from the RAAF General AAP NDT&CT = Inspections requiring NDT&CT Development

0 USN/RCAF 1 RAAF Gen. 0 NDT&CT







DAVENG-DASA, LOTEX Brief to DD ASI, Feb 2017



•  ADF lost confidence in management of PC-9/A ASIP –  Degradation, Condition Monitoring and

Fatigue Management System (SCMS and FMS))

–  Complex ICA –  Recommendations backlog –  Configuration control –  Certification issues –  Successive small extensions to PWD

limiting the feasibility of large scale improvements.


Case Study 2 - PC-9/A ASIP Recovery - Overview Structural

configuration not accurately

captured

Unable to assess

effectiveness of EDM programs and establish

emerging trends

Unclear structural inspection

policy and gaps in fatigue

certification

ASIP Recovery Project



•  Fleet-wide audit to determine structural configuration of fatigue critical locations.

•  Inspection layout based on consolidated ASIMP Volume 2.

•  Example Findings –  Non-standard repairs versus repair authorised by latest ICA / SBI policy –  Stop drilled cracks in SBI locations do not adhere to current repair policy

•  Also, new structural condition database ‘VISION’ used to record all NDT reports, structural defects and Other Configuration Records (OCRs).


Case Study 2 - PC-9/A ASIP Recovery – Fleet-wide Inspection



Case Study 2 - PC-9/A ASIP Recovery – SBI Location Consolidation & ICA Revision

•  Example - Frame 9: –  SBI to include all inspection locations and configurations –  rather than having four different SBI locations with –  varying thresholds and intervals

that require different NDT reports, etc.

•  Consolidation improved clarity and efficiency of the SBI program by –  reducing the number of inspections and –  rationalising inspection intervals

•  End to end audit of SBI ICA to identify deficiencies.

•  Revision of current ICA / SBI policy to: –  Ensure all inspections included in NDT manual. –  Simplify implementation policy



Case Study 2 - PC-9/A ASIP Recovery – Outcomes Fleet-wide structural audit

to establish structural configuration and inspect

aft fuselage locations

+

SCMS Reinvigoration Project (TASPO)

Review EDMP effectiveness and trend SCM data (routine ASIP

task)

Desktop audit of all Safety By Inspection (SBI) instructions for

continued airworthiness (ICA) to identify FM

deficiencies

+

Address fatigue certification

recommendations backlog

+

Repackage Safety By Inspection (SBI) program and SBI Instructions for Continued Airworthiness

(ICA)

Establish a robust and efficient ASIP

!

! !

Revise ASIMP Vol2 and all supporting ICA: configuration, include fatigue management for non-

baseline configuration, outcomes from OLM program



•  High instances of cracking detected within RAAF fleet

•  RAAF accrual of aft fuselage buffet usage

•  Location managed by limited Inspection and on condition replacement

•  Are the inspections sufficient?


Case Study 3 – FA-18A/B Bootstraps – Wide Area Inspection



•  Bootstrap Surface Finish –  Ion Vapour Deposit (IVD) Aluminium Coating –  Primer –  Thermal Foam, Adhesive & Sealant –  Numerous WHS complications to remove on a large scale

•  Wide Area Inspection – Process –  Water picking – sealant and foam removal –  Wide Area BHEC and SSEC Inspection –  Crack Indications excised for Forensic Examination –  Hot (80deg) Nitric Acid (50%) Etching –  Wide Area Close Visual Inspection –  Crack Indications excised for Forensic Examination

•  Structural Integrity Implications still to be assessed


Case Study 3 – FA-18A/B Bootstraps – Wide Area Inspection



•  Aircraft Structural Integrity Program –  ensure the desired level of structural safety, performance, durability, and supportability with the least possible economic

burden throughout the aircraft’s service life

•  F/A-18A/B LOTEX –  Achieved through combination of Engineering Analysis and Non Destructive Inspection

•  PC-9/A ASIP Recovery –  Degraded ASIP through reactive SBI Program development and continued proximity to PWD –  Recovery achieved though end to end audit of ICA, Fleet wide Inspection & SBI location consolidation

•  Bootstraps Wide Area Inspection –  Is the existing inspection program adequate?


Summary



Documents

Aircraft Structural Integrity – Engineering and NDT Case ... · NDT&CT = Inspections requiring NDT&CT Development 0 USN/RCAF 1 RAAF Gen. 0 NDT&CT 0 USN/RCAF 2 RAAF Gen. 0 NDT&CT