> **NOTICE**
>
> This document is disseminated under the sponsorship of the United
> States Department of Transportation in the interest of information
> exchange. The United States government assumes no liability for the
> contents or use thereof. The United States government does not endorse
> products or manufacturers. Trade or manufacturers' names appear herein
> solely because they are considered essential to the objective of this
> training curriculum.
>
> **ACKNOWLEDGMENTS**

Development of this course was funded by the Federal Aviation
Administration Technical Center, Atlantic City, New Jersey under grant
number 93G018. The work was performed at the FAA Center for Aviation
Systems Reliability at Iowa State University under the guidance of the
FAA NDT Training Design Panel. The materials were designed in
cooperation with Aircraft Certification Service and Flight Standard
Service personnel for training of Aviation Safety Inspectors.

The contributions of the members of the NDT Training Design Panel are
gratefully acknowledged: Alfred L. Broz, FAA National Resource
Specialist for NDE; Bernie Borenstein, Principle Maintenance Inspector;
Flight Standards Service; Lisa J.H. Brasche, CNDE Associate Director,
Iowa State University; Carmen S. Delgado, NDI Course Manager, FAA
Academy; John M. Fabry, Manager, FAA Technical Center;
Robert E. Guyotte, Manager, Engine Certification Branch; Chris J.
Heizer, Training Program Analyst, Aircraft Certification Service; Bruce
A. Kotzian, Principle Maintenance Inspector; Flight Standards Service;
Isabel Kulick, Training Program Analyst, Aircraft Certification Service;
Nancy C. Lane, Training Program Analyst, Aircraft Certification Service;
and Fred Sobeck, Aging Aircraft Program Manager; Flight Standards
Service.

In addition, many members of the aviation industry have supported the
development of this course in the form of guidance, materials, overview,
and samples. These include members of the Air Transport Association NDT
Network, Boeing Commercial Airplane Corporation, Douglas Commercial
Aircraft, General Electric Aircraft Engines, Pratt & Whitney Engines,
Northwest Airlines, Northwest Airlink, and the Aging Aircraft NDE
Validation Center at Sandia National Laboratories.

Course materials were prepared by Lisa Brasche, Associate Director, CNDE
and Program Manager for FAA-CASR; and Anita L. Ousley, Training
Specialist, FAA-CASR. Many of the CASR staff supported in preparation
and review of materials with significant assistance provided by Linda R.
Poore, Program Assistant, FAA-CASR; Brian F. Larson, Engineer, CNDE; and
Dave Utrata, Engineer, CNDE.

  --------------------------------------------------- ----------------------------------------------------
  ![](media/image1.emf){width="2.672222222222222in"   ![](media/image2.emf){width="1.0569444444444445in"
  height="0.35138888888888886in"}                     height="1.0840277777777778in"}

  --------------------------------------------------- ----------------------------------------------------

####  Nondestructive Inspection  {#nondestructive-inspection .1heading}

#### (NDI) {#ndi .1heading}

#### Evaluation Checklist {#evaluation-checklist .1heading}

####  {#section .1heading}

The NDI evaluation checklist is a tool to be used in certification,
audit/evaluation, and surveillance of nondestructive testing facilities.
This checklist is designed to provide a standardized approach to
evaluate an NDI facility.

The NDI evaluation checklist is organized around five elements which are
used to assess the facility's ability to perform NDI functions. These
five elements comprise a systematic NDI evaluation process that can be
utilized in evaluation of any NDI organization, from manufacturing to
maintenance. The five elements: documentation, organization,
environment, calibration, and training, are defined below:

> Documentation - written procedures, processes, specifications and/or
> methods used by air operators or air agencies in the performance and
> control of NDI activities.
>
> Organization - relationship of NDI organization to management.
>
> Environment - the general physical condition of the facility, e.g.,
> housekeeping, storage, safety, consumable management, equipment.
>
> Calibration - process by which an item is checked against a standard.
>
> Training - methods used and records maintained to train and retrain
> NDI personnel.
>
> These elements represent the underlying system that needs to be in
> place for a satisfactory NDI operation. Using the NDI evaluation
> checklist provides the Aviation Safety Inspector (ASI) with a
> standardized approach to assess compliance. Not all questions in the
> checklist need to be addressed in all situations, nor is it necessary
> to have an affirmative response to all questions. The ASI exercises
> judgment in determining compliance based on the facility's ability to
> present reasonable and defensible response to the issues contained in
> the checklist.
>
> The checklist is organized in two parts: Application of the Systematic
> NDI Evaluation Process; and NDI Methods. Application of the Systematic
> NDI Evaluation Process includes a general section to record pertinent
> information about the facility, followed by questions applicable at
> certification, audit/evaluation, and surveillance for each of the five
> elements. Many of the questions under certification are also
> applicable during audit/evaluation and surveillance. The NDI Methods
> section includes specific questions for the six most commonly used
> techniques: Visual, Liquid Penetrant, Magnetic Particle, Eddy Current,
> Ultrasonics, and Radiography.
>
> The checklist is provided as a tool to be used in preparation for
> evaluation of NDI facilities. It is not intended to be used as a
> checkoff form during on‑site visits.
>
> This document is disseminated under the sponsorship of the United
> States Department of Transportation in the interest of information
> exchange. The United States government assumes no liability for the
> contents or use thereof. The United States government does not endorse
> products or manufacturers. Trade or manufacturers' names appear herein
> solely because they are considered essential to the objective of this
> document.

**Table of Contents**

> **[Systematic NDI Evaluation Process]{.smallcaps}**
>
> General 4
>
> Certification 5
>
> Documentation 5
>
> Organization 6
>
> Environment 7
>
> Calibration 8
>
> Training 9
>
> Audit/Evaluation and Surveillance 10
>
> Documentation 10
>
> Organization 10
>
> Environment 11
>
> Calibration 11
>
> Training 11
>
> **[NDI Methods]{.smallcaps}**
>
> Visual Inspection 13
>
> Liquid Penetrant Inspection 15
>
> Magnetic Particle Inspection 17
>
> Eddy Current Inspection 20
>
> Ultrasonic Inspection 22
>
> Radiography 24

#### General {#general .Sect.-Header-2}

[Facility Name and Address:]{.smallcaps}

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

[Certificate number
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}

[Certificate types:]{.smallcaps}

[\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_[\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}

[Principal Contact:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Type of Inspection(s) Performed

  ------------------- -------------------- ------------------------------
  Visual              Liquid Penetrant     Magnetic Particle

  Eddy Current        Ultrasonic           Radiography
  ------------------- -------------------- ------------------------------

Other\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

[Type of Evaluation]{.smallcaps}

Initial certification or approval

Scheduled audit/evaluation

Surveillance

[Date of Current Evaluation
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}

[Date of Last Evaluation
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_]{.smallcaps}

#### Certification {#certification .Sect.-Header-2}

Certification involves the evaluation of the manner in which prospective
air operators or air agencies intend to conduct business to assure
compliance with all applicable regulatory requirements. The process is
designed to identify applicants who comply with regulatory requirements
and conform to safe practices. The certification process requires
completion of three steps: analyze the data, assure its implementation,
and verify its use. Since there is limited specific regulatory guidance
that focuses on NDI, a systematic NDI evaluation process has been
developed to evaluate the initial submittal of data by the facility on
the NDI operation to assure compliance.

#### Documentation {#documentation .Section-Header}

  -----------------------------------------------------------------------
  Does the facility have a manual?

  Does the manual contain an NDI organizational chart?

  Does the manual contain or refer to the appropriate NDI specifications
  for which approval is requested?

  Are the NDI specifications current?

  Are the NDI specifications available?

  Are there provisions in the manual for internal review or evaluation of
  compliance to the manual?

  Are records of such reviews or evaluations kept?

  Are there procedures in place to revise the manual?

  Are there procedures in the manual for the retention of inspection
  records?

  Does the manual contain procedures that address nonconformities?

  Are manuals and procedures available to and used by the qualified
  personnel?

  Does the manual contain controls for subcontracts for NDI services?

  Does the manual contain controls for management of NDI products,
  materials, and consumables?
  -----------------------------------------------------------------------

#### Organization {#organization .Section-Header}

  -----------------------------------------------------------------------
  Is there a separate NDI organization within the facility?

  Does the NDI manager or equivalent have direct line authority to the
  NDI qualified personnel?

  Are NDI requirements provided to the NDI inspection personnel by use of
  written procedures?

  Does the NDI manager, or equivalent, review the quality assurance
  system to monitor compliance to the FAA approved data?

  Are proper shift change procedures in place to assure communication of
  inspection status and to assure inspection is properly performed and
  interpreted?
  -----------------------------------------------------------------------

####  Environment {#environment .Section-Header}

Facility description

NDI work area size
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Number of NDI inspectors (by level if appropriate):

Total \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

NDI subcontractors (list subcontractors utilized and type of inspection
authorized)

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Type of equipment:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

  -----------------------------------------------------------------------
  Is the size of the NDI work area sufficient to perform the NDI
  inspections?

  Is there adequate work area for the storage and separation of NDI
  materials? (equipment, standards, chemicals, supplies)

  Is there a method for controlling and segregating nonconforming NDI
  equipment and materials?

  Are appropriate manuals, procedures, and other documentation available
  for use by qualified personnel?

  Are adequate parts handling systems (cranes, hoists, lifts, etc.)
  available to the inspectors?

  Do routing documents specify the operations needed and in what
  sequence?

  Is adequate protection provided to parts during handling and routing?

  Is metal-metal contact of finished surfaces prevented during handling?

  Are obsolete documents removed from inspection areas?
  -----------------------------------------------------------------------

#### Calibration {#calibration .Section-Header}

  -----------------------------------------------------------------------
  Is there a procedure for calibrating inspection devices to certified
  standards?

  Are there procedures for the segregation of functional and
  nonfunctional equipment?

  Are procedures in place to ensure repaired equipment is recalibrated?

  Are reference standards properly labeled, stored, and used?

  Are independent data available for reference standards, i.e., drawings,
  metrology, etc.?

  Are the calibration methods documented?

  Do calibration methods include environment controls, standards to be
  used, and accuracy requirements?

  Are setup verifications performed on all shifts as appropriate?
  -----------------------------------------------------------------------

####  Training (Classroom, OJT and Demonstration of Performance) {#training-classroom-ojt-and-demonstration-of-performance .Section-Header}

  -----------------------------------------------------------------------
  Are training requirements identified in the manual for the methods
  used?

  Are training, qualification, and certification done in accordance with
  criteria such as:
  -----------------------------------------------------------------------

> Snt-TC-1A Recommended Practice for Personnel Qualification and\
> Certification in Nondestructive Testing

Mil Standard 410-E

ATA 105

Other
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

  -----------------------------------------------------------------------
  Are there procedures for maintaining training records for NDI
  personnel?

  Is there a procedure to include OJT requirements and is it recorded?

  Is there a procedure to include demonstration of performance and is it
  recorded?

  Is all data pertinent to individual
  training/certification/recertification on file?

  Is there a procedure for recertification/decertification of NDI
  personnel?
  -----------------------------------------------------------------------

####  Audit/Evaluation & Surveillance {#auditevaluation-surveillance .Sect.-Header-2}

Audit/evaluation and surveillance are significant components of an ASIs
responsibilities. Audit/evaluation includes verification that the
certificate or approval holder meets all regulatory requirements and is
operating in compliance with material approved during the
certification/approval process. Surveillance includes assuring that
compliance is maintained in the day-to-day operations of the air agency
for the certificate that they hold. There is limited specific regulatory
guidance that focuses on NDI. A systematic NDI evaluation process has
been developed to evaluate the NDI operation to assure compliance and
consists of five elements: Documentation, Organization, Environment,
Calibration, and Training. The issues identified in the certification
section are also applicable to audit/evaluation and surveillance.

#### Documentation {#documentation-1 .Section-Header}

  -----------------------------------------------------------------------
  Have any changes been made to the manual since initial approval or last
  audit/evaluation?

  Were the proper revision procedures followed in making any changes to
  the manual?

  Has retention of required records been met?
  -----------------------------------------------------------------------

#### Organization {#organization-1 .Section-Header}

  -----------------------------------------------------------------------
  Have any organizational changes been made since the original
  certification/approval or audit/evaluation?

  Are the changes included by revision to the manual?
  -----------------------------------------------------------------------

####  Environment {#environment-1 .Section-Header}

  -----------------------------------------------------------------------
  Have any changes been made to the working environment that would
  inhibit or enhance the performance of NDI inspections since the
  original certification/approval or most recent audit/evaluation?

  Are the changes included as revisions to the manual?

  Are the inspection devices of the type, range, accuracy and precision
  appropriate to the product or process?
  -----------------------------------------------------------------------

#### Calibration {#calibration-1 .Section-Header}

  -----------------------------------------------------------------------
  Are calibration records kept?

  Are calibration records current?

  Are materials with expiration dates managed using appropriate
  procedures?
  -----------------------------------------------------------------------

#### Training {#training .Section-Header}

  -----------------------------------------------------------------------
  Is the facility in compliance with requirements for its training
  records and procedures?

  Is the facility in compliance with its recertification requirements?

  Is the facility in compliance with its decertification requirements?

  Are qualified personnel available for all required techniques and at
  all the required levels called for in the manual?
  -----------------------------------------------------------------------

####  Nondestructive Inspection Methods {#nondestructive-inspection-methods .Sect.-Header-2}

Nondestructive inspection (NDI) involves the use of a collection of
techniques that allow a determination of the integrity of a component,
material, or structure without compromising the usefulness of the
product. NDI is used by the aviation industry for defect detection,
geometrical measurement, and materials characterization. The six most
commonly used inspection methods are covered in this checklist and
include: visual inspection, liquid penetrant inspection, magnetic
particle inspection, eddy current inspection, ultrasonic inspection, and
radiographic inspection. A brief description is provided for each of the
techniques, followed by a series of questions that are applicable in
evaluation of an NDI facility that practices the technique, and the
items that may be included in a procedure employing the method.

#### Visual inspection {#visual-inspection .Section-Header}

Visual inspection is the process of using the eye, alone or in
conjunction with various aids, as the sensing mechanism from which
judgments may be made about the condition of a unit being inspected.

  -----------------------------------------------------------------------
  Are procedures in place to define the visual inspection process?

  Are procedures in place to ensure inspection is documented?

  Are precautions taken to ensure that procedures that can adversely
  affect visual inspection are not performed prior to the inspection
  process?

  Is adequate lighting available for the tasks at hand?

  Is adequate time allowed for eye adaptation when changes in light
  intensity occur (going from dark to light areas or vice versa)?

  Is a training program in place for visual inspection?

  Are procedures in place to ensure that visual inspectors possess
  binocular vision with good visual acuity?

  Are inspectors using specific targets rather than scanning a particular
  area (i.e., looking at individual rivets as opposed to scanning a lap
  splice)?

  Are flashlights of appropriate quality and intensity used for the
  inspection?

  Are appropriate safety approvals in place for use when recommended in
  hazardous atmospheres?

  Are borescopes, fiberscopes, and other remote viewing equipment
  properly stored and maintained?

  Do inspectors have proper training for the instruments they are using?
  -----------------------------------------------------------------------

**Written Procedures for Visual Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance, the adherence to the procedures
should be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written .bullet1}

## Part identification including material and alloy, and routing slip {#part-identification-including-material-and-alloy-and-routing-slip .bullet1}

## Sequence of visual examination {#sequence-of-visual-examination .bullet1}

##  Identification of test standards for system performance verification {#identification-of-test-standards-for-system-performance-verification .bullet1}

## Areas of the part to be examined {#areas-of-the-part-to-be-examined .bullet1}

## Part preparation {#part-preparation .bullet1}

## Use of visual tools such as flashlights, calipers, micrometers, rulers, and magnifying devices {#use-of-visual-tools-such-as-flashlights-calipers-micrometers-rulers-and-magnifying-devices .bullet1}

## Type of visual instruments (videoscopes, borescopes, fiberscopes) and recording device if appropriate {#type-of-visual-instruments-videoscopes-borescopes-fiberscopes-and-recording-device-if-appropriate .bullet1}

## Acceptance requirements {#acceptance-requirements .bullet1}

## Record keeping and method for marking parts after examination {#record-keeping-and-method-for-marking-parts-after-examination .bullet1}

## Operator's name {#operators-name .bullet1}

## Author and reference to original FAA approved data  {#author-and-reference-to-original-faa-approved-data .bullet1}

#### Liquid Penetrant {#liquid-penetrant .Section-Header}

Liquid penetrant inspection is used to reveal **surface breaking**
cracks in solid, nonporous materials. While both fluorescent and
nonfluorescent techniques are available, most aviation applications
involve the use of fluorescent penetrants in a bulk process. A series of
steps involving precleaning, application of penetrant, removal of excess
penetrant, application of developer, and examination under appropriate
light, and postcleaning, is needed.

  -----------------------------------------------------------------------
  Is the proper light (black light or visible light) used for the
  penetrant inspection?

  Is proper light intensity determined on a regular basis?

  Are proper dwell times, dry times, and temperatures followed?

  Are gages, thermometers, and timers used to control the process
  adequate?

  Are procedures followed properly to ensure that penetrant is not
  removed from cracks when excess penetrant is being removed from the
  surface?

  Is the examining area free of interfering debris and "stray"
  fluorescent materials?

  Are procedures in place to assure inappropriate mixing of solutions
  (penetrants, emulsifiers and developers) does not occur?

  Are tanks protected from possible contamination?

  Are procedures in place to ensure precleaning and postcleaning is
  performed properly?

  Is the correct penetrant sensitivity being used?

  Are test panels used to verify system performance?

  Are surface preparation procedures properly performed (e.g., paint
  removal)?

  Are process controls in place for each step of the procedure and are
  they checked at regular intervals?

  Is the penetrant solution compared to a standard for brilliance and
  color?

  If dry developer is used, is it dry, fluffy and free of fluorescence?
  -----------------------------------------------------------------------

**Written Procedures for Liquid Penetrant Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance the adherence to the procedures should
be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written-1 .bullet1}

## Part identification including material and alloy {#part-identification-including-material-and-alloy .bullet1}

##  Sequence of liquid penetrant examination {#sequence-of-liquid-penetrant-examination .bullet1}

## Identification of test standards for system performance verification {#identification-of-test-standards-for-system-performance-verification-1 .bullet1}

## Areas of the part to be examined {#areas-of-the-part-to-be-examined-1 .bullet1}

## Part preparation including method of cleaning {#part-preparation-including-method-of-cleaning .bullet1}

## Drying procedure (time and temperature) {#drying-procedure-time-and-temperature .bullet1}

## Temperature limits of materials and surface of part {#temperature-limits-of-materials-and-surface-of-part .bullet1}

## Type of liquid penetrant material to be used and the method and equipment to be used for its application {#type-of-liquid-penetrant-material-to-be-used-and-the-method-and-equipment-to-be-used-for-its-application .bullet1}

## Dwell time for penetrant solution {#dwell-time-for-penetrant-solution .bullet1}

## Procedure for removal of excess penetrant {#procedure-for-removal-of-excess-penetrant .bullet1}

## Procedure for application of developer including dwell time {#procedure-for-application-of-developer-including-dwell-time .bullet1}

## Acceptance requirements {#acceptance-requirements-1 .bullet1}

## Post-cleaning instructions {#post-cleaning-instructions .bullet1}

## Record keeping and method for marking parts after examination {#record-keeping-and-method-for-marking-parts-after-examination-1 .bullet1}

## Inspector's name {#inspectors-name .bullet1}

## Procedure author and date  {#procedure-author-and-date .bullet1}

#### Magnetic Particle {#magnetic-particle .Section-Header}

Magnetic particle inspection is used to find **surface and near surface
defects** in **ferromagnetic** materials. Fluorescent and
nonfluorescent, wet and dry methods are available but most aviation
applications involve use of the wet fluorescent method in a batch
processing system which is the most sensitive. Parts are usually
magnetized in at least two directions at right angles to each other and
**demagnetization** of the part is required.

  -----------------------------------------------------------------------
  Are procedures in place to ensure that only ferromagnetic materials
  will be inspected?

  Is the correct light type (visible or black light) used?

  Are procedures in place to magnetize the component in sufficient
  orientations to ensure that all flaws are found?

  Is a reference standard(s) available to measure magnetic field
  strength?

  Are procedures in place for demagnetization of the part?

  Are procedures in place to remove paint or coatings if required?

  Is black light intensity checked on a regular basis?

  Is the examining area free of interfering debris and "stray"
  fluorescent materials?

  Are appropriate maintenance procedures for the inspection equipment
  followed as recommended in the equipment manuals or required by the
  facility's documentation?

  Are surface preparation procedures properly performed (e.g., paint
  removal)?

  Is bath concentration measured using established procedures?

  Are reference standards taken through the same procedure as a part,
  including demagnetization?

  Are procedures in place to ensure that particles which have lost their
  color or have become stuck together are discarded?

  Can the magnetization equipment obtain the required amperage specified
  by the procedures?

  Are the solvents used approved by the manufacturer?

  Are central conductors used to inspect circular parts if necessary?

  Is the equipment capable of adequately demagnetizing the part?

  Is there a documented cleaning process to be followed prior to
  inspection?

  Does the known defect test part have defects of similar or smaller size
  than the smallest acceptable size for the part being inspected?

  When the defect test part is processed, is the defect revealed?

  Does suspension of magnetic particles adequately wet the part?

  Is suspension checked for contamination at established intervals?

  After processing, are parts cleaned to remove evidence of magnetic
  substances?

  Are parts demagnetized and checked with a field meter?

  Are detailed written procedures available for each part?

  Is each step of the procedure signed off?

  Do adequate procedures exist for calibrating equipment?
  -----------------------------------------------------------------------

**Written Procedures for Magnetic Particle Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance the adherence to the procedures should
be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written-2 .bullet1}

## Part identification including material and alloy {#part-identification-including-material-and-alloy-1 .bullet1}

## Sequence of magnetic particle examination {#sequence-of-magnetic-particle-examination .bullet1}

## Identification of test standards for system performance verification {#identification-of-test-standards-for-system-performance-verification-2 .bullet1}

## Areas of the part to be examined {#areas-of-the-part-to-be-examined-2 .bullet1}

## Part preparation {#part-preparation-1 .bullet1}

## Position instructions of part with respect to magnetizing equipment {#position-instructions-of-part-with-respect-to-magnetizing-equipment .bullet1}

## Type of magnetizing current and equipment including use of head, coil, yoke, etc {#type-of-magnetizing-current-and-equipment-including-use-of-head-coil-yoke-etc .bullet1}

## Current level or the number of ampere turns to be used and the duration of its application {#current-level-or-the-number-of-ampere-turns-to-be-used-and-the-duration-of-its-application .bullet1}

## Type of magnetic particle material to be used and the method and equipment to be used for its application {#type-of-magnetic-particle-material-to-be-used-and-the-method-and-equipment-to-be-used-for-its-application .bullet1}

## Directions of magnetization {#directions-of-magnetization .bullet1}

## Acceptance requirements {#acceptance-requirements-2 .bullet1}

## Demagnetization and post cleaning instructions {#demagnetization-and-post-cleaning-instructions .bullet1}

## Rust prevention treatments {#rust-prevention-treatments .bullet1}

## Record keeping and method for marking parts after examination  {#record-keeping-and-method-for-marking-parts-after-examination-2 .bullet1}

#### Eddy Current {#eddy-current .Section-Header}

Eddy current testing is used to find **surface and near surface
defects** in **conductive materials**. It is used by the aviation
industry for defect detection such as cracks, corrosion damage, and
thickness verification, and for materials characterization such as metal
sorting and heat treatment verification. Applications range from
fuselage and structural inspection, to engines, to landing gear, to
wheels and is the technique most often used after visual. Eddy current
inspection involves **intensive setup and calibration** procedures with
known **reference standards** of the same material as the part. Probes
of appropriate design and frequency must be used.

  -----------------------------------------------------------------------
  Are appropriate probes and instrumentation being used as called for in
  the established procedure?

  Are appropriate procedures being followed to set up the instrument
  using reference standards of the same material and geometry as the test
  piece before each inspection?

  Is scan direction chosen to ensure that the probe scans across the
  potential crack direction?

  Are recommended templates and guides being used?

  Do qualified personnel have proper training for the instrument they are
  using (meter vs. impedance plane)?

  Are inspectors careful to minimize probe wobble during scanning?

  If protective tape is used during the inspection, is it also used
  during setup and calibration?

  Are procedures in place to ensure that defective probes are removed
  from service?

  Are recommended maintenance and calibration procedures being followed?
  -----------------------------------------------------------------------

**Written Procedures for Eddy Current Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance the adherence to the procedures should
be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written-3 .bullet1}

## Part identification including material and alloy {#part-identification-including-material-and-alloy-2 .bullet1}

## Sequence of eddy current examination {#sequence-of-eddy-current-examination .bullet1}

## Identification of test standards for system performance verification {#identification-of-test-standards-for-system-performance-verification-3 .bullet1}

## Areas of the part to be examined {#areas-of-the-part-to-be-examined-3 .bullet1}

## Part preparation {#part-preparation-2 .bullet1}

## Frequency, probe type, scanning speed {#frequency-probe-type-scanning-speed .bullet1}

## Type of eddy current instrument and recording device, if appropriate {#type-of-eddy-current-instrument-and-recording-device-if-appropriate .bullet1}

## Setup procedures {#setup-procedures .bullet1}

## Acceptance requirements {#acceptance-requirements-3 .bullet1}

## Record keeping and method for marking parts after examination {#record-keeping-and-method-for-marking-parts-after-examination-3 .bullet1}

## Operator's name  {#operators-name-1 .bullet1}

#### Ultrasonics {#ultrasonics .Section-Header}

Ultrasonic inspection uses high frequency sound waves to interrogate the
component for **internal** **flaws** via a transmitting transducer. Both
single transducer (where one transducer serves as sender and receiver,
known as reflection) and dual transducer (where one transducer serves as
sender and the others as receiver, known as transmission) methods are
used. The ultrasonic method is used to determine the presence of
interior flaws, measure thickness or determine material properties.
Typical applications **require fluid couplants** to transmit the sound
from the transducers to the part. Both contact (use of gel couplant) and
immersion (submerge part in water or other approved fluid) are used.

  -----------------------------------------------------------------------
  Are appropriate transducers and couplants being used as called for in
  the established procedure?

  Are appropriate procedures being followed to set up the instrument
  using appropriate reference standards?

  Do inspectors have proper training for the equipment and procedures
  being utilized?

  Are procedures in place to ensure defective transducers and equipment
  are removed from service?

  Are transducers placed properly as defined by the inspection procedure?

  Are recommended maintenance and instrument calibration procedures being
  followed?

  Are procedures in place to ensure glycerin is not used on aluminum
  materials as it causes corrosion?

  Are precautions taken to ensure air bubbles do not exist in immersion
  inspection systems?

  Are equipment records available for preventative maintenance checks
  reflecting frequency, results, and accuracy of axis movements in
  immersion systems?

  Are there sufficient setup standards for all parts being inspected?

  Is there a procedure which includes an inspection plan for each part
  being inspected?
  -----------------------------------------------------------------------

**Written Procedures for Ultrasonics Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance the adherence to the procedures should
be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written-4 .bullet1}

## Part identification including material and alloy {#part-identification-including-material-and-alloy-3 .bullet1}

## Sequence of ultrasonic examination {#sequence-of-ultrasonic-examination .bullet1}

## Identification of test standards for system performance verification {#identification-of-test-standards-for-system-performance-verification-4 .bullet1}

## Areas of the part to be examined {#areas-of-the-part-to-be-examined-4 .bullet1}

## Part preparation {#part-preparation-3 .bullet1}

## Frequency, transducer type, couplant {#frequency-transducer-type-couplant .bullet1}

## Type of ultrasonic instrument and recording device if appropriate {#type-of-ultrasonic-instrument-and-recording-device-if-appropriate .bullet1}

## Calibration procedures {#calibration-procedures .bullet1}

## Acceptance requirements {#acceptance-requirements-4 .bullet1}

## Record keeping and method for marking parts after examination {#record-keeping-and-method-for-marking-parts-after-examination-4 .bullet1}

## Operator's name  {#operators-name-2 .bullet1}

#### Radiography {#radiography .Section-Header}

Radiography uses radiation energy to detect variations in x-ray
attenuation in the object under test and can be used to **detect
inclusions, voids, cracks**, and **changes in geometry or material
properties**. Two types of radiation energy are typically used by the
aviation industry: **x-rays** which are produced by electronic
generators; and, gamma rays which are produced by **isotope** sources.
Radiography can be used to **inspect most materials** for both surface
and internal flaws but **orientation** of flaw and source is
**critical.**

  -----------------------------------------------------------------------
  Does the facility use x-ray radiography (electronic generators)?

  Does the facility use gamma radiography (isotope sources)?

  Are safety procedures in place for the handling and use of ionizing
  radiation?

  Are radiation areas marked?

  Is mandatory regulatory guidance available?

  Are written procedures available?

  Are procedures which specify tube voltage, tube current, and exposure
  time or isotope source and exposure time available and adhered to?

  Are required film types available and properly handled and stored?

  Are procedures in place to ensure film is not mishandled or switched?

  Are procedures in place to ensure that recommended source to film
  distances called for in the procedure are used?

  Are procedures in place to ensure proper alignment of the x-ray
  generator with respect to the part being inspected?

  Are procedures in place to ensure that film processing chemicals and
  film are properly stored and used?

  Are required image quality indicators (IQIs) available?

  Are adequate darkroom facilities available and are they properly
  maintained and clean?

  Are recommended maintenance procedures followed for light boxes and
  illuminators?

  Are evaluation criteria provided which include type, size, shape,
  orientation, and location of flaw?

  Are accept/reject criteria available?

  Is adequate handling equipment available for the parts to be tested?

  Is the film read and evaluated prior to return to service for the part,
  plane, or engine?

  Is there a program in place to monitor radiation exposure (film badges,
  dosimeters, survey meters, etc.)?

  Are temperature controls in place and operable on processing equipment?

  Are timing devices in place and operable on processing equipment?

  Are replenishing devices in place and operable on processing equipment?

  Is film viewing equipment in good working condition?

  For reading radiographs, is background illumination controllable to a
  maximum of 2.5 foot candles of ambient light?

  Is adequate information indicated on the film?
  -----------------------------------------------------------------------

**Written Procedures for Radiographic Inspection**

During certification, written procedures should be required, which are
applicable to the part or group of parts being tested. During
audit/evaluation and surveillance the adherence to the procedures should
be verified. Procedures may include the following elements:

## Procedure number and date written {#procedure-number-and-date-written-5 .bullet1}

## Description or sketch of object {#description-or-sketch-of-object .bullet1}

## Material type and thickness {#material-type-and-thickness .bullet1}

## Source to film distance {#source-to-film-distance .bullet1}

## Part preparation {#part-preparation-4 .bullet1}

## Film type {#film-type .bullet1}

## Film density {#film-density .bullet1}

## Screen type and thickness {#screen-type-and-thickness .bullet1}

## Isotope or x-ray machine identification {#isotope-or-x-ray-machine-identification .bullet1}

## Tube current milliamperage or radio isotope source strength {#tube-current-milliamperage-or-radio-isotope-source-strength .bullet1}

## Kilovoltage settings {#kilovoltage-settings .bullet1}

## Exposure time {#exposure-time .bullet1}

## Film placement {#film-placement .bullet1}

## Source position {#source-position .bullet1}

## Critical orientation or defect location instructions {#critical-orientation-or-defect-location-instructions .bullet1}

## Penetrameter (IQI) and shim thickness {#penetrameter-iqi-and-shim-thickness .bullet1}

## Penetrameter placement {#penetrameter-placement .bullet1}

## Special masking or filters {#special-masking-or-filters .bullet1}

## Collimator, shielding of field limitation devices {#collimator-shielding-of-field-limitation-devices .bullet1}

## Film processing methods {#film-processing-methods .bullet1}

## Standard reference radiographs that may be used {#standard-reference-radiographs-that-may-be-used .bullet1}

## Record keeping and method for marking parts after examination {#record-keeping-and-method-for-marking-parts-after-examination-5 .bullet1}

## Acceptance requirements {#acceptance-requirements-5 .bullet1}

## Sign off for the inspector interpretation {#sign-off-for-the-inspector-interpretation .bullet1}