GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN SEES6 PROJECT A330

REFERENCE G54RP1310441

ISSUE 1.0 DATE 6 Mar 2013

© AIRBUS OPERATIONS S.A.S. 2013. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.
Page 1 of 11 

# GE CF6-80E1 - ATA 54-51-18 Fractured Bolts on Aft Engine Mount Upper Beam.

TABLE OF CONTENTS

1 DESCRIPTIONS ................................................................................................................. 2

1.1 GENERAL ....................................................................................................................... .... 2

1.2 PREFERRED INSPECTION ............................................................................................... 2

2 PROCEDURES ................................................................................................................... 2

2.1 TASK SUPPORTING DATA ................................................................................................ 2

2.1.1 AREA OF APPLICABILITY (SEE FIGURE 1) ............................................................ 2

2.1.2 DESCRIPTION OF POSSIBLE DAMAGE ................................................................. 2

2.1.3 REASON FOR THE JOB ........................................................................................... 2

2.1.4 JOB SET UP INFORMATION .................................................................................... 3

2.2 PROCEDURE ..................................................................................................................... 3

2.2.1 EQUIPMENT AND MATERIALS ................................................................................ 3

2.2.2 PREPARATION FOR INSPECTION .......................................................................... 3

2.2.3 INSTRUMENT ADJUSTMENT .................................................................................. 4

2.2.4 INSPECTION ............................................................................................................. 4

2.2.5 ACCEPTANCE CRITERIA ......................................................................................... 5

2.2.6 FINAL NDT REQUIREMENTS ................................................................................... 5



## TABLE OF FIGURES Figure 1: Inspection Area. .................................................................................................... ............. 6 Figure 2: Example of Crack & Section C-C of bolt head. .................................................................. 7 Figure 3: Signal from V1 block with alarm gate. ............................................................................... . 8 Figure 4: Probe Position ...................................................................................................... .............. 9 Figure 5: Signal from good bolt (section C-C fig 2). ........................................................................ 1 0 Figure 6: Signal from cracked Bolt. ........................................................................................... ...... 11GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

REFERENCE

ISSUE 1.0 DATE

© AIRBUS OPERATIONS S .A.S. 2013. ALL RIGHTS RESERVED. CONF IDENTIAL AND PROPRIETARY DOCUMENT.

Page 2 of 11 

## 1 DESCRIPTIONS

1.1 GENERAL

A. This procedure contains the technical information for the inspection of GE CF6-80E1– ATA 54-51-18 Bolts ( PN 1672M36P01 x4 per Engine) on Aft Engine Mount Upper Beam.

B. This procedure is applicable for the detection of 100% cracked sheared through bolts (Fig 1 & 2)



### 1.2 PREFERRED INSPECTION

See

A. GE CF6-80E1 - ATA 54-51-18 Fractured Bolts on Aft Engine Mount Upper Beam

B. No alternative.



## 2 PROCEDURES

2.1 TASK SUPPORTING DATA

NTM 51-40-00



### 2.1.1 AREA OF APPLICAB ILITY (SEE FIGURE 1)

Bolt Part Number (PN) 1672M36P01, Aft Engine Mount Upper Beam attached to the pylon,



### 2.1.2 DESCRIPTION OF POSSIBLE DAMAGE

A. Cracks completely sheared through the bolt section (Figure 2)



### 2.1.3 REASON FOR THE JOB

See AOT A71L002-13GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 3 of 11 

### 2.1.4 JOB SET UP INFORMATION

A. TOOLING:

ID Item Designation Key Parameters Tooling
Used to Develop

The
Procedure Vendor

USN 60 - Ultrasonic Equipment UIDBCAB y G.E. Inspection Technologies

- - Cable Lemo 1 to lemo 0 y G.E. Inspection Technologies

MB2S EN 500038 - Ultrasonic search unit 2MHz Dia 10mm y G.E. Inspection Technologies

V1 (EN12223) - Calibration Block Steel y G.E. Inspection Technologies

NOTE: Any comparable Ultrasonic equipment may be used provided that it satisfies the requirements of this procedure and is capable of resolving the reference signal in the calibration standard at the required level of resolution.



### 2.2 PROCEDURE

2.2.1 EQUIPMENT AND MATERIALS

See 2.1.4 (A) TOOLING.



### 2.2.2 PREPARATION FOR INSPECTION

A. Make sure the Access Panel has been removed refer to AOT A71L002-13..

B. Make sure that the surface to be inspected is clean and smooth.

C. Check the inspection area for any visible damage or discontinuities.GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 4 of 11 

### 2.2.3 INSTRUMENT ADJUSTMENT

Set the data given below on the instrument:

Frequency: 2 MHz Range: 200 mm Delay: 0.000 μ s MTL Velocity: 5960 m/s (0.126 in. / μ s)
Rectification mode: full wave

A. Connect appropriate search unit MB2S EN 500038 to instrument.

B. Couple the search unit to the V1 block (A330 NTM Figure 51-00-991-102A) on the 100mm section (Figure 3),

C. Adjust the position of the search unit to get a reflection at 50 divisions on the time base and the repeat echo at 100 divisions (See Fig 3).

D. Adjust the instrument gain control to give a 100 % Full Screen Height (FSH) signal.

E. Set the Gate Start Marker to 50 mm.

F. Set the Gate Marker width to 60 mm

G. Set Gate to 30%, full Screen Height

Caution:
CONFIRM THE V1 BLOCK MATCHES EN 12223 IN RESPECT OF THE 100MM SECTION
AND THE MATERIAL VELOCITY OF 5920MM/S. THE BOLT MATERIAL IS INCONEL AND
THE VELOCITY WILL NOT EXACTLY MATCH THE V1 BLOCK. THIS IS TAKEN INTO
ACCOUNT WITH THE GATE SETTINGS. THE INTENTION OF THE PROCEDURE IS TO IDENTIFY 100% SHEARED BOLTS IN THE ANTICIPATED LOCATION, NOT TO GIVE A
PRECISE MEASUREMENT OF THE OVERALL LENGTH.



### 2.2.4 INSPECTION

A. Couple the search unit on the threaded end of the bolt. (Fig 4 & 5)

B. Adjust the position of the search unit until you achieve the signal (Fig 5)

Note: Figure 2 shows the section view of the reflecting face of the bolt head. Expected beam path approx 110mm (4.311”). The bolt head has more than one possible configuration (see fig 2 detail C-C) when interpreting the backwall echo this should be taken into account.GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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© AIRBUS OPERATIONS S .A.S. 2013. ALL RIGHTS RESERVED. CONF IDENTIAL AND PROPRIETARY DOCUMENT.

Page 5 of 11 

### C. Record all indications > 30 % on the Time base, within the length of the bolt (Fig 6)

D. Repeat Steps A to C for the remaining bolts to be inspected.



### 2.2.5 ACCEPTANCE CRITERIA

A. Reject all bolts which show indications within the length of the bolt > 30 % FSH (Fig 6) and
record them as cracked.

B. Report all cracked bolts to Airbus.



### 2.2.6 FINAL NDT REQUIREMENTS

Remove couplant and clean the inspection surface.GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 6 of 11 Annex of Figures

Rib 8D1:

Bolts to be inspected 1 thru 4.

Figure 1: Inspection Area. 1

2 3

4GE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 7 of 11 Figure 2: Example of Crack & Section C-C of bolt head. Search unit position for inspection Typical sheared bolt (Through Crack)



### C

C

C CGE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 8 of 11 Figure 3: Signal from V1 block with alarm gate. 

### Gate 30%, 50mm start 60mm width 100 mm
section

First Repeat Echo from 100 mm
section Echo from 100 mm Section 100% FSHGE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 9 of 11 Figure 4: Probe Position 

## Probe Position Center of Bolt threaded endGE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

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Page 10 of 11 Figure 5: Signal from goo d bolt (section C-C fig 2). 

### Gate 30%, 50mm start 60mm widthGE CF6-80E1 - ATA 54-51-18 FRACTURED BOLTS ON AFT ENGINE MOUNT

UPPER BEAM Technical Report ORIGIN PROJECT A330

REFERENCE

ISSUE 1.0 DATE

© AIRBUS OPERATIONS S .A.S. 2013. ALL RIGHTS RESERVED. CONF IDENTIAL AND PROPRIETARY DOCUMENT.

Page 11 of 11 Figure 6: Signal from cracked Bolt. 

### Gate 30%, 50mm start 60mm width