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Measurement & Control

GE Inspetion Technologies
Surface Inspection with
the Mentor EM
How Am I Going to Do That ??

• Share Customer Stories


• Discuss Typical Applications and Surface
Probes
• Review Key Elements of Airframe
Manufacturer’s Inspection Procedures
• Perform Surface Inspections with the
Mentor EM

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Customer North American Regional Air
Story Carrier

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What’s Important for this Regional Air Carrier ?

The EM inspection is the easy part;


use high frequency absolute probes

• Quickly locating correct inspection


procedures
• Making sure they’re inspecting in
the correct location
• Making on-site decisions to release,
repair, or replace components

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Typical Aerospace Surface Crack Inspection
Applications
Vertical & Horizontal
Stabilizers

Engines /
Pylons
Undercarriage /
Fuselage / Stringers /
Doublers Wheels

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Customer Story Airframe Manufacturer

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What’s Important for an Airframe Manufacturer ?

• Assurance their inspection


procedures are being followed
• Making it easy for their
customers to locate and follow
the inspection procedures

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Hmmmmm…..??????

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Boeing 767 Inspection - Upper Sill Service Door

Calibration

Instrument
Inspection Procedure
Probe
Standard

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Boeing 767 Inspection - Upper Sill Service Door

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Absolute Surface Pencil Probe Families

Frequency Shape
Shielding Length
200 kHz Straight
Shielded 2, 3, 4.5, 6,
500 kHz + or + 8, 12 in. + 90 Degree
2 MHz 15 Degree
Unshielded ….
6 MHz BoltHole

Often
application
specific

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Absolute Surface Pencil Probe Families

Frequency Shape
Shielding Length
200 kHz Straight
Shielded 2, 3, 4.5, 6,
500 kHz + + 8, 12 in. + 90 Degree
or
2 MHz DON’T BE INTIMIDATED BY THE 15 Degree
Unshielded ….
6 MHz BoltHole
NUMBER OF PROBES….THE
INSPECTOR USUALLY HAS HIS
PREFERRED PROBE FOR THE
SPECIFIC INSPECTION

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Absolute Pencil Probe Scan of AL Calibration Block

LIVE MENTOR DEMO

AL Test Block with Machined Notches

Lift
off Edge Balance Point
Effect
0.5 mm
EDM
Notch
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Customer Story Aircraft Wheel and Brake Manufacturer

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What’s Important for this Wheel & Brake Manufacturer

• Simple interface
• Minimal training for non-NDT
mechanics
• Speed of inspection
• Assurance of 100% coverage

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Popular Surface Inspection Applications

1. Surface crack detection on aluminum or


steel structures with absolute pencil probes
2. Industrial Weldscan applications
3. Automated inspection of roto-symetrical
components
4. Sub-layer corrosion in aerospace structures

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Industrial WeldScan Surface Applications

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Inspection of Roto Symmetrical Components

Application: Automotive components for


surface breaking cracks
• Axles, bearings, spindles…

Typical Customer: Tier 2 Auto Manufacturers

Solution: Differential eddy current probes


• Highly sensitive to sharp discontinuities
• Insensitive to slow changes
• Probe orientation critical for defect
detection

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Sub-Layer Corrosion Detection for Aircraft Structures

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Sub-Layer Corrosion Detection for Aircraft Structures

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Sub-Layer Corrosion Detection for Aircraft Structures

Application: Corrosion detection in


multi-layer aircraft fuselage

Typical Customer: Air Carriers

Solution: Reflection probes


• Larger diameter
• Low frequency for deep
penetration
• Also works well for sub-layer
crack detection

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Boeing Application for Reflection Style Sliding
Probe
More challenging inspection
but same core elements:
• Instrument (& alternatives)
• Probe (& alternatives)
• Reference Standard
• Inspection Procedure

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Surface Inspection and the Mentor EM

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Boeing 767 Inspection - Upper Sill Service Door

Calibration

Instrument Inspection Procedure


Probe
Standard

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Absolute Pencil Probe Scan of AL Calibration Block

AL Test Block with Machined Notches

Lift
off Edge Balance Point
Effect
0.5 mm
EDM
Notch
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Mentor EM Phasec Expert GUI

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Mentor EM Practical Exercise

What you will need:


• Mentor EM in Phasec
Expert mode
• 2 MHz absolute pencil
probe
• Probe cable and aluminum
(aluminium) crack block

What you will do: Lift


1. Duplicate probe response off Edge Balance Point
Effect
and screen image 0.5 mm
EDM
2. Add sector gate Notch
3. Optimize display for your
viewing
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Mentor EM Practical Exercise

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Mentor EM Practical Exercise

Lift
off Edge Balance
Effect Point
0.5 mm
EDM
Notch

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Mentor EM Phasec Expert GUI

Generate clean signal…then…see impact of…


• Frequency
• Drive Voltage
• Drive Percentage
• Receiver Gain
• …………

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Your Next Steps

1. Be able to discuss the value of the Mentor EM for your


customers application
2. Continue to become proficient with your Mentor EM demo
unit…practice…practice…practice
3. Order demo EM probe kits…if you do not have them
already
4. Deliver and train-on the Mentor beta units in your region
• Customer training is the key; both EM and Create
5. Work with your RSD and develop a plan for training of
your regional sales teams
6. Ensure your RSD orders Mentor EM demo units for his
regional sales team
7. Be prepared to implement your regional training plan
when Bob & Wade give the green light 35
CLOSE

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Absolute Surface Pencil Probes for Crack
Detection

Essential Info
• Single coil highly sensitive to cracks
• Typically ‘shielded’ in ferrite or steel
tube to minimize ‘edge’ effect
• Most common ‘center’ frequencies:
• 200 kHz, 500 kHz, and 2 MHz
• Boeing prefers 200 kHz
• Airbus prefers 2 MHz
• 200 kHz best for ferrous/steel
• Many shapes to accommodate
complex shapes, access issues, and EC Field
obstructions
• Teflon tape used to protect coil tip

Coil
Ferrite
Core 37
Differential Scanning Probes for Crack Detection

Essential Info
• Two balanced coils wound on ferrite cores
• Highly sensitive to sharp discontinuities
• Insensitive to slow changes in the material
• Often used for rapid scanning of steel
components; i.e. automotive
• Probe orientation critical for defect detection
• Typical inspection frequency: ~200 to 500
kHz Coil Ferrite Cores
s

Balance
Point
Coils

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Reflection Probes for Near-Surface Inspection

Essential Info
• Two basic designs: driver-pick up and
absolute-pick up
• Deep material penetration in non-ferrous
mat’l
• Used widely in the aero apps to find cracks
and corrosion in multi-layer structures
• Large scan area with low frequency probes
• Typical inspection frequency: ~20 to 100 kHz Ferrite Cores

Pick-up
Coils
‘C’ EDM Drive
r Coil
‘B’ EDM

Lift-Off ‘D’ EDM


Driver Pick-
‘A’ Balance Coil up
Point 39
Coils
T Surface Inspection Demo Kits

Absolute Pencil Probes Reflection Probes


• Shielded: Straight, 90, • 0.5 in dia.; 300 Hz to 100 kHz
45, and 15 degree • 1 in. dia.; 80 Hz to 60 kHz
• Unshielded straight • Unshielded straight
• 200 kHz and 2 MHz • Cables
• Differential probe • Demo block for sub layer
• Cables corrosion
• Aluminum and steel
blocks

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