~DUN:£OP ,£.

IlWZrBD
GENERAL PRACTICES MANUAL
NOT AI RCRAFT WHEELS

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101
102
103
104
105
106

201
202
203
204
205
206
207
208

List of Effective Pages

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GENERAL PRACTICES MANUAL
NDT AI RCRAFT WHEELS

Description
System Operation
Interpretation

Description
System Operation
Interpretation

201

201

201

202
Systems Using a Meter Display
Systems Using a Chart Recorder
Systems Using a Storage Oscilloscope

2:0-00-01 'CONT8NTS
Page 1
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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

This General Practices Manual contains information on detailed examination of

aircraft wheels for cracks using Non-Destructive Testing Techniques as laid
down by Dunlop Aviation. This manual will be updated as and when new types
of equipment become available. If further information is required contact
Dunlop Aviation Division, Holbrook Lane, Coventry.

Introduction
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GENERAL PRACTICES MANUAL
NDT AI RCRAFT WHEELS

Page

Wheel Preparation 202

Flange Rim/Tyre Seat

Peripheries of Bolt Holes
Radii in Nut and Bolt Head Seats

·0·
Peripheries of Ventilation/Lightening
Ring Seal Groove
Radii Under Drive Block Abutments
Holes

Web Radii
Lock Ring Groove
Inner Wall Radii in Centre Flange

Fig.

NDT Specified Inspection Areas Main Wheel (Typical) 1

Typical Circumferential Scan Pattern 101
Typical IIMetoptic EM1211 Test Set Up 102
Typical IIlnspection Instrument Eddyprobe 411 Test Set Up 103
Typical Circumferential Scan Pattern 201
Typical Sinusoidal Scan Pattern 202
Typical Scan Paths Peripheries of Bolt Holes 203
,_/

Typical Scan Path Nut and Bolt Head Seat Radii 204
Typical Scan Path Peripheries of Ventilation/
Lightening Holes 205
Typical Scan Path '0· Ring Seal Groove 206
Typical Scan Pattern Radii Under Drive Block Abutments 207
Typical Scan Path Web Radii 208
Typical Scan Paths Lock Ring Groove 209
Typical Scan Patterns Inner Wall Radii 210

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GENERAL PRACTICES MANUAL
NOT AI RCRAFT WHEELS

1. Description

In the 'Check' section of the Component Maintenance Manual for an aircraft

wheel a sectional illustration details the areas in which NOT inspection is
required. A large number of these areas can be covered by the common
inspection techniques outlined in this manual. Areas specific to a particu-
lar wheel only will be covered in the relevant wheel Component Maintenance
Manual.

It is the object of this manual to detail techniques that will reveal fatigue
cracking of aircraft wheels in the order of 2 mm (0.08 in.) long 0,25 mm
(0.01 in.) deep.

A. Flange rim/tyre seat: critical area, preferred method of inspection

Semi-Automated Eddy Current.

Particular care must be paid to the inspection of the flange rim/

tyre seat area (reference area A) as small cracks and defects in
this area may result in rapid crack propagation, causing a sec-
tion of flange to become detached. It is important that the tech-
niques employed are capable of finding defects of the order des-
cribed in para.2 Object.

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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

Semi-Automated Eddy Current inspection is the preferred method of inspec-

tion for the flange to tyre seat area. A number of test sets and techniques
are available, examples of which are described. Reference should also be
made to test set manufacturers instructions.

The scan pattern used in a semi-automated eddy current technique is nor-

mally circumferential, as illustrated in Figure 101. The pitch of the scan
path being determined by the type of test set and probe used. The com-
plete barrel area of the wheel may be scanned, on large wheels the mini-
mum amount of tyre seat area scanned is to be 50 mm (2 in.).

SCj~P'T(:H,J·.R..··.·.··.R··.·.·••R•••·.~·I;'~:R-:-_-I·.·.·.·.E·
(
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.~."~
•••••.
~it"",)

Clean the area to be inspected as detailed in 'Cleaning' section of Compo-

nent Maintenance Manual. Remove loose paint and tyre rubber in the
flange rim radius and tyre seat area.

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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

'O'RING SEAL
GROOVE
VE~TILATION I (BRAKE SIDE
LIGHTENING HOLES HALF HUB)
(BOTH HALF HUBS)

DRIVE DOG
ABUTMENTS
(BRAKE SIDE
HALF HUB)

To carry out adequate and effective crack detection using Eddy

Current Equipment a trained operator should be available and
the limitations of the techniques and test equipment appreciated.

Page 2
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GENERAL PRACTICES MANUAL
NOT AIRCRAFT WHEELS

000\=U
CRACK DETECTOR AND
RECORDER UNIT

PROBE ARM
PROBE ARM
GUIDE
RAM

: 000 I
i 000 I

/ ~~~/I'J[ ~:,~
CONTROL PANEL PROXIMITY
qbl>

SWITCHES

This system is designed for use with a trace recorder having two
paper speeds. Two probe types are utilised, one contoured to fit
individual tyre seat radii and containing two scanning cores to cover
the flange to tyre seat radius and the tyre seat radius to the start
of the tyreseat area. It is important that the profile of this probe
matches that of the bead seat radius of the hub being inspected. Air
gaps between the probe and hub will result in a loss of sensitivity.
The other probe has a flat section to cover the tyre seat and barrel
area. This probe has a scan area of 9 mm (0.35 in.) coupled with a
circumferential scan path of 2 mm (0.08 in.) pitch, thus any defect
will be scanned at least three times. To facilitate setting up of the
system a calibration block containing a real or artificial crack 0,5 mm
(0.02 in.) deep approximately 0,1 mm (0.004 in.) wide is required.

The inspection probes described to cover the flange rim and

tyre seat radius can be employed manually using a simple
turntable.

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GENERAL PRACTICES MANUAL
NDT AI RCRAFT WHEELS

This system incorporates a chart recorder with a fixed paper feed and
utilises an inspection probe with a spherical tip that is sensitive over
a full 360 degrees at its contact point. The system gives a circumfer-
ential scan of approximately 1,6 mm (0.062 in.). To facilitate setting
up of the system a calibration block containing a real or artificial
crack 0,5 mm (0.02 in.) deep approximately 0,1 mm (0.004 in.) wide
is required.

(1) Adjust lift off control to give minimal test meter needle movement
when probe is lifted slightly from test block.

(2) Adjust meter sensitivity to give a signal trace height of 15 mm

(0.6 in.) on recording paper for the 0,5 mm (0.02 in.) deep
defect in the calibration block.

(4) Set upper and lower proximity switches to pre-determined posi-

tions (X and Y Figure 102) ensuring lower switch is set to give
a scan start at the outer edge of the flange area (point X Figure
102) and upper switch to give a scan at least 50 mm (2 in.) into
the tyre seat area (point Y Figure 102).

Scan may be extended to include complete barrel area of

wheel if desired.

C. Interpretation

(1) View recording trace, investigate any signal trace of 5 mm (0.2

in.) height or greater using a hand held probe and a high fre-
quency test meter.

(3) Corrosion is not permitted, dress out corrosion as detailed in

'Repair' section of Component Maintenance Manual.

(4) Dress out physical damage as detailed in 'Repair' section of

Component Maintenance Manual.

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(1) With cable connected to one connection of the contoured probe,

adjust trace sensitivity to give a signal height of 15 mm (0.6 in.)
on the recording paper for the 0,5 mm (0.02 in.) deep defect in
the calibration block.

It is recommended that a series of hubs or hub sections

be obtained with tyre seat radius profiles to match the
contoured probes being used and contain known fatigue
cracks in the tyre seat radius. Spark eroded or milled
slots 0,5 mm (0.02 in.) deep 0,1 mm (0.004 in.) to
0,2 mm (0.008 in.) wide, 6 mm (0.25 in.) to 8 mm
(0.3 in.) long may be used. At the start of each
wheel batch these hubs should be used to calibrate
the test equipment ..

(2) Select turntable speed to 1, trace recorder speed to high, turn-

table/recorder synchronisation to 'ON'. Place probe in tyre seat
radius, depress auto zero button, switch turntable on. Scan
hub for two full revolutions.

(3) Connect cable to the opposite connection of contoured probe.

Repeat steps (1) and (2).

(4) Connect cable to the tyre seat/barrel probe, calibrate as per

step (1). Select turntable speed 4, trace recorder speed to low,
position probe to overlap scan area of contoured probe. Switch
turntable on. Scan tyre seat/barrel area for at least 50 mm
(2 in.). Switch off.

Scan may be extended to include the complete barrel

area of wheel if desired.

(1) View recording trace. Investigate any signal trace of 5 mm (0.2

in) in height or greater using a hand held probe and a high
frequency test meter.

(2) Reject a cracked half hub.

(3) Corrosion is not permitted, dress out corrosion as detailed in

I Repair' section of Component Maintenance Manual.

(4) Dress out physical damage as detailed in •Repair' section of

Component Maintenance Manual.

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NDT AIRCRAFT WHEELS

0 0 0 C
[]0
]0 0 1
I
g C
,
0 C
I 0

/ I
\l=I ~
0
CJ r
/0
CONTROL PANEL
0
i,

_I

CRACK DETECTOR
AND RECORDER UNIT

SCAN
SCAN SCAN
OVERLAP OVERLAP
SCAN

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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

Manual eddy current inspection can be applied to all areas listed, including
the flange to tyre seat area when semi-automated eddy current techniques
are not available, providing the hubs are fully disassembled apart from
removing the bearing outer races. A wide range of test sets are available
falling into two main categories; high frequency sets operating with a signal
frequency above 1 MHz, low frequency sets operating below 1 MHz. In
addition to the following procedures reference should also be made to test
set manufacturers instructions when inspecting wheel hubs.

A. Various inspection probes are utilised during manual eddy current

inspection, the most common types are:

(1) Non ferrous point probes, used in conjunction with fixed high
frequency test sets. The standard forms of the probe are:

(a) 'pi type (pencil)

(b) 'KI type (knife)

(2) Differential probes used in conjunction with low frequency test

sets operating at approximately 30 KHz. These probes may take
the following forms:

(a) 10 mm (0.39 in.) long with a 2 mm (0.08 in.) radiused tip,

used to inspect tyre seat radii.

(b) 10 mm (0.39 in.) diameter flat probe, used to inspect tyre

seat area.

(c) Probes moulded to the form of the flange rim to tyre seat
area. These probes will contain separately wound cores
which give an extended area of coverage.

(3) Non ferrous point probes used with variable frequency test sets
at around 200 KHz. These probes are held in probe guides con-
toured to fit into the scan area.

A. To allow setting up of a test set a calibration sample is required.

This may be one of the following types.

(1) Standard non ferrous test block containing a slot 0,5 mm (0.02
in.) deep 0,1 mm (0.004 in.) wide.

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GENERAL PRACTICES MANUAL

NDT AI RCRAFT WHEELS

(2) Hub or hub section containing a known fatigue crack 0,5 mm

(0.02 in.) deep and 2 mm (0.08 in.) to 4 mm (0.16 in.) long in
the flange rim/tyre seat area.

(3) Hub or hub section containing an artificial defect in the flange

rim/tyre seat radius. This should take the form of a spark ero
ded or milled slot 0,5 mm (0.02 in.) deep and 3 mm (0.12 in.) to
4 mm (0.16 in.) long with a maximum width of 0,2 mm (0.008 in.).

A. Systems Using a Meter Display

Obtain a full scale deflection from the 0,5 mm (0.02 in.) deep, real
or artificial defect in calibration sample. Set the audio/visual alarm
to trigger at half scale deflection.

Some test sets have an audio/visual alarm which triggers

at a fixed position e. g. 40%of scale deflection. In this in-
stance the 0,5 mm (0.02 in.) deep defect should be set to
80%of scale deflection. Test equipment with other fixed
trigger levels should be adjusted accordingly.

Adjust the sensitivity so that the 0,5 mm (0.02 in.) deep real or
artificial defect produces a signal height of 15 mm (0.6 in.) on the
recording paper.

Adjust the equipment so that the 0,5 mm (0.02 in.) deep real or
artificial defect, produces at least a half screen height image.

5. Wheel Preparation

Clean all areas to be inspected as detailed in ·Cleaning' section of Compo-

nent Maintenance Manual. Remove loose paint and tyre rubber from flange
rim radius and tyre seat area, ensure nut and bolt head seat radii are free
from jointing compound.

To ensure a satisfactory scan pitch is maintained a coating of

dye penetrant developer can be sprayed on to the scan area.
During inspection the scan pitch will be traced in this coating
allowing it to be monitored.

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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

(1) Two scan patterns may be used in this area, circumferential and
sinusoidal. Either is acceptable providing complete coverage is
achieved.

(2) Using a pencil probe inspect flange rim and tyre seat area using
a circumferential scan as illustrated in Figure 201. Amplitude of
scan IA1 should be 50mm (2 in.) minimum, scan IB1 15 mm (0.6 in.)
minimum. The pitch of scan IC' will be determined by the fre-
quency of the probe and test set used, e.g. 1 mm (0.04 in.) for
high frequency equipment operating at 1 MHz or over, 2 mm
(0.08 in.) for lower frequency equipment operating at 200 KHz.
It is recommended that whenever possible an indexing device and
turntable be employed to ensure an even scan pitch.

Typical Circumferential Scan Pattern

Figure 201

(3) Using a pencil type probe inspect flange rim and tyre seat using
sinusoidal scan patterns as illustrated in Figure 202. Amplitude
of scan IA1 should be 50 mm (2 in.) minimum, scan IB1 15 mm
(0.6 in.) minimum. The pitch of scans ID1 should be 2 mm (0.08
in.) maximum.

I
SCAN PATH
OVERLAP

Typical Sinusoidal Scan Pattern

Figure 202 20-00-01 Page 203
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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

Using a pencil type probe inspect the peripheries of bolt holes on

both sides of half hub as illustrated in Figure 203. The distance of
scan from bolt hole should be 1 mm (0.04 in.).

If the probe is allowed to veer on to the edge of bolt

hole meter needle deflection will occur. These deflec-
tions should not be confused with those caused by a
defect.

To ensure a satisfactory scan at the required distance

from holes, locally produced non-metallic bungs with
a lip of appropriate size may be used as a probe guide.

Using a pencil probe inspect the nut and bolt head seat radii as
illustrated in Figure 204.

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NDT AIRCRAFT WHEELS

Using a pencil probe inspect the peripheries of ventilation/lightening

holes on both sides of half hub as illustrated in Figure 205. The
distance of scan from edge of hole should be 2 mm (0.08 in.).

Typical Scan Path Peripheries of Ventilation/Lightening Holes

Figure 205

Using a knife type probe inspect the '0' ring seal groove with both
sinusoidal and circumferential scan patterns as illustrated in Figure
206. The minimum scan pitch for both scan patterns should be 2 mm
(0.08 in.) .

./

/
"'- /

'~

.
,

" ::
/ /

Typical Scan Path '0' Ring Seal Groove

Figure 206
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GENERAL PRACTICES MANUAL
NDT AIRCRAFT WHEELS

Usng a pencil probe inspect the radii under drive block abutments
using a sinusoidal scan pattern as illustrated in Figure 207 the pitch
of scan X should be 2 mm (0.08 in.) with an amplitude of 5 mm
(0.2 in.). Scan should extend 5 mm (0.2 in.) beyond the edges of
drive block abutment.

This inspection is only feasible when drive blocks and heat

shields are removed.

Typical Scan Pattern Radii Under Drive Block Abutments

Figure 207

Using a miniature pencil probe inspect the web radii as illustrated in

Figure 208. c'--"""

Typical Scan Path Web Radii

Figure 208

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GENERAL PRACTICES MANUAL
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Using a special miniature knife type probe inspect the lock ring groove
using sinusoidal and circumferential scan patterns as illustrated in
Figure 209. The scan pitch for the sinusoidal scan should be 2 mm
(0.08 in.) for the circumferential scan 1 mm (0.04 in.).

'O'RING SEAL GROOVE

REFER TO FIG 206

Using a pencil probe inspect the inner wall flange radii using sinu-
soidal and circumferential scan patterns as illustrated in Figure 210.
The pitch for both scan patterns should be 2 mm (0.08 in.).

FlANGEITYRE SEAT AREAS ...

REFER TO FIG 201/202------... .. ~

(
~(/

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