TSD594-J - Section 2 - Inspection

TSD
SECTION 2
INSPECTION
LIST OF EFFECTIVE PAGES

OVERHAUL OVERHAUL OVERHAUL
PROCESS PAGE DATE PROCESS PAGE DATE PROCESS PAGE DATE
Printed in Great Britain
70-00- 70-00- 70-00-

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201 1 Oct.1/02 210 5 May 1/01 216 3 Dec.1/95
201 2 Oct.1/02 210 6 May 1/01 216 4 Dec.1/95
201 3 Oct.1/02 210 7 May 1/01 216 5 Dec.1/95
201 4 Oct.1/02 210 8 Oct.1/02 216 6 Dec.1/95
201 5 Oct.1/02 210 9 May 1/01 216 7 Dec.1/95
201 6 Oct.1/02 210 10 May 1/01 216 8 Dec.1/95
201 7 Oct.1/02 210 11 May 1/01 216 9 Dec.1/95
201 8 Oct.1/02 210 12 May 1/01 216 10 Dec.1/95
201 9 Oct.1/02 210 13 May 1/01 216 11 Dec.1/95
201 10 Oct.1/02 210 14 May 1/01 216 12 Dec.1/95
201 11 Oct.1/02 210 15 May 1/01 216 13 Dec.1/95
201 12 Oct.1/02 210 16 May 1/01 216 14 Dec.1/95
201 13 Oct.1/02 210 17 May 1/01 216 15 Dec.1/95
201 14 Oct.1/02 210 18 May 1/01 216 16 Dec.1/95
201 15 Oct.1/02 210 19 May 1/01 218 1/ Dec.1/95
201 16 Oct.1/02 210 20 May 1/01 2
201 17 Jun.1/02 210 21 May 1/01 219 1 Dec.1/95
201 18 Jun.1/02 210 22 May 1/01 219 2 Dec.1/95
201 19 Apr.5/99 210 23 May 1/01 219 3 Dec.1/95
201 20 Jun.1/02 210 24 Jul.5/04 219 4 Dec.1/95
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201 28 Apr.5/99 210 32 May 1/01 219 12 Dec.1/95
201 29/ Apr.5/99 210 33 May 1/01 219 13/ Dec.1/95
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203 1/ Dec.1/95 210 35 May 1/01 220 1 Dec.1/95
2 210 36 May 1/01 220 2 Dec.1/95
205 1 Nov.1/03 210 37 May 1/01 220 3 Dec.1/95
205 2 Dec.1/95 210 38 May 1/01 220 4 Dec.1/95
205 3 Nov.1/03 210 39 May 1/01 220 5 Dec.1/95
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205 6 Dec.1/95 210 42 May 1/01 220 8 Dec.1/95
205 7/ Dec.1/95 210 43 May 1/01 220 9 Dec.1/95
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208 1 Dec.1/95 210 45 May 1/01 220 11/ Dec.1/95
208 2 Dec.1/95 210 46 May 1/01 12
208 3 Dec.1/95 210 47/ May 1/01 221 1 Dec.1/95
208 4 Dec.1/95 48 221 2 Dec.1/95
208 5 Dec.1/95 213 1/ Nov.1/01 221 3 Dec.1/95
208 6 Dec.1/95 2 221 4 May 1/03
208 7 Dec.1/95 214 1 Dec.1/95 221 5 Dec.1/95
208 8 Dec.1/95 R 214 2 Jul.5/05 221 6 May 1/03
208 9 Dec.1/95 R 214 3 Jul.5/05 221 7 May 1/03
208 10 Dec.1/95 R 214 4 Jul.5/05 221 8 May 1/03
208 11 Dec.1/95 R 214 5 Jul.5/05 221 9 May 1/03
208 12 Dec.1/95 R 214 6 Jul.5/05 221 10 May 1/03
208 13 Dec.1/95 215 1 Jun.1/96 222 1 Nov.1/03
208 14 Dec.1/95 215 2 Jun.1/96 222 2 Nov.1/03
208 15/ Dec.1/95 215 3 Jun.1/96 222 3 Nov.1/03
16 215 4 Jun.1/96 222 4 Nov.1/03
210 1 May 1/01 215 5/ Jun.1/96 222 5 Aug.1/98
210 2 May 1/01 6 222 6 Aug.1/98
210 3 May 1/01 216 1 Dec.1/95 222 7 Aug.1/98
210 4 May 1/01 216 2 Dec.1/95 222 8 Aug.1/98
LIST OF EFFECTIVE PAGES - SECTION 2
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OVERHAUL OVERHAUL OVERHAUL
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223 7 May 1/01
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LIST OF EFFECTIVE PAGES - SECTION 2

Page 2
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TSD
OVERHAUL PROCESS 201
MAGNETIC PARTICLE INSPECTION

TASK 70-00-00-200-201 Overhaul Process 201 - Magnetic Particle

Inspection
SUBTASK 70-00-00-860-201-051
1. Materials used in the Overhaul Process
OMat 101 Kerosine

OMat 1/260 Odourless kerosine
OMat 608 Magnetic ink (fluorescent)
OMat 612 Magnetic particle inspection flux indicator
SUBTASK 70-00-00-860-201-052
2. Make-up of Magnetic Ink
A. Magnetic ink (fluorescent)
Working concentration 0.1 to 0.5 % OMat608 magnetic ink in OMat1/260

odourless kerosine
SUBTASK 70-00-00-180-201-001
3. Control of Equipment and Materials
A. Refer to SUBTASK 70-00-00-860-201-051 for list of materials used in this

process.
B. Frequency and control of maintenance checks
A record shall be kept to show that the control and maintenance checks have
been compleated, this should record the result of the checks and the action
taken to rectify those checks which were not satisfactory.
(1) Annual
Ultra-violet (u/v) monitors and white light meters must be calibrated

using a method traceable to a national standard.
Pocket field strength indicators, refer to para F.

EFFECTIVITY: TSD594-J 70−00−00
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(2) Six Monthly
Ammeters, refer to para E.
(3) Monthly

Ultra-violet lamp efficiency, refer to O.P.210 (TASK 70-00-00-200-210).
White light level at inspection area, refer to O.P.210 (TASK

70-00-00-200-210).
Magnetising units, refer to para J.
(4) Weekly
Ink fluorescence, refer to para D.
(5) Shift
Magnetic ink partical content and contamination, refer to para C.
Process performance test piece, refer to para H.
Tank levels, refer to para I.
Pocket field strength indicaters, refer to para G.
C. Magnetic ink particale content and contamination
The checks should be made as follows;
(1) With the ink agitated by the normal method in use, take a 100 ml.
sample in a gradulated flask.
(2) Allow the sample to settle for 1 hour.
(3) Check the solid particle concentration which should fall within the
specified range.
(4) Inspect the sample for contamination. Clean ink will show a sharp
demarcation line between fluids and solids. If the seperation is
indistinct the tank should be drained and thoroughly cleaned before
refilling with fresh ink.
(5) Maintain the particle concentration to the required level by adding

more fluid or solid content as necessary.
NOTE: The magnetic ink should also be checked for particle content and
contamination when a fresh quantity is mixed and after each
correction or replenishment.

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D. Ink fluorescence
(1) When the machine is filled with a new quantity of ink a glass container
should be filled from the machine using normal applicator. This sample
should be tightly stoppered and stored in a cool dark place until
required for comparison.
(2) A sample of the used ink (normally the sample used for ink content
check), taken after normal agitation, is compared under an ultra-violet
light for fluorescent brightness/intensity.
(3) When there is a visible difference in fluorescent brightness between

the used ink and the stored sample,the tank shall be drained and be
replaced with new ink.
E. Ammeters
(1) These should be checked against a calibrated master instrument A max

tolerance of plus or minus 10 percent from the master instrument is
permitted.
(2) This is achieved by placing a suitable shunt connected to a digital

voltmeter or oscilloscope between the headstocks of the machine and
taking a minimum of five readings over the working range of the
ammeter.
(3) When the difference between the two readings is greater than 10 percent
corrective action must be taken.
F. Pocket field strength indicators
(1) These should be checked against a direct magnetic field of known

strength to ensure they comply to the manufacturer's specification.
(2) Also check to make sure that there is no obvious damage, that the meter
needle is at zero (plus or minus 0.5 division) when the meter is
horizontal and with the meter vertical and the centre line horizontal
the needle is not free to move more than one division.
G. Process performance test piece
(1) Details of standard test pieces are given in Fig

70-00-00-990-201-001-001, Fig 70-00-00-990-201-001-002 and Fig
70-00-00-990-201-002. For DC machines a KETOS ring may be used as an
alternative to the test pieces shown.
(2) Using fresh ink, the current values necessary to detect each hole
should be noted and permanently recorded for each magnetising method on
the machine.

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(3) Monitoring of the performance of equipment, materials and technique is

carried out by magnetising the test pieces using the current values
recorded in (2). Failure to detect the holes using the recorded values
indicates the ink or machine ammeter or other equipment is not
performing correctly. Corrective action must then be taken to correct
the fault and the performance test repeated.

H. Tank levels
Check tank levels and replenish as necessary.
I. Magnetising units
Inspect the condition and functioning of equipment such as ammeters, wander

leads, control switches and gauze contact pads for wear or damage. Replace
or repair as necessary. Inspect and clean the filters if fitted to the
magnetic particle ink supply.
SUBTASK 70-00-00-860-201-053
4. Safety Precautions
A. The health and safety data given are general guidelines in use at
Rolls-Royce, it is the responsibility of the operator/user to obtain
detailed health and safety data for the materials in use and refer to local
regulations to ensure safe working practice.
SUBTASK 70-00-00-860-201-054
5. General
A. Magnetic particle inspection (MP) is a non-destructive method of detecting

discontinuities (cracks, inclusions etc.) located at the surface or near
the surface of parts in ferro-magnetic alloys; it cannot be used for
non-magnetic alloys which includes Austenitic steels.
This process describes the various magnetising methods used to detect

defects using MPI. The methods shall be used when specified in the Engine
Manual. Also information is included on alternative techniques, according
to equipment available, that can be used to accomplish the methods
specified.
125Watt 'self filtered bulb' ultra-violet lamps are not acceptable for use
on Rolls-Royce engine parts. Ultra-violet lights must have separate woods
filter and typically use a 100 Watt mercury vapour pre-focused bulb.
Inspection personnel shall be approved by the appropriate regulatory

authority.

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The selection of the methods is governed by the size and shape of the part
and the direction in which the magnetic field is to be created. The Engine
Manual will specify the appropriate methods, amperage requirements,
inspection requirements, and any other relevent details to detect possible
defects in the parts
B. The following abbreviations are those used in the Engine Manual.
A=Axial
R=Radial
C=Circumferential
L=Longitudinal
T=Transverse
TB=Threading bar
CTB= Centralised Treading Bar
OTB= Offset Threading Bar
MF=Magnetic flow
CI=Current induction
CF=Current flow
CFC= Current Flow Clamp (End to End)
CFD= Current Flow Diametrical
AC= Alternating current
HWRAC=Half-wave rectified AC
FWRAC=Full-wave rectified AC
A/T=Ampere turns
FMI=Fluorescent magnetic ink
RMS=Root mean square

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C. Inking Methods
(1) Detecting inks consist of finely divided ferro-magnetic particles

suspended in a suitable carrier fluid, usually odourless kerosine. The
particles may be coloured with fluorescent dye to give an acceptable
contrast to the surface when inspection is done under ultra-violet

light.
(2) The ink should be kept thoroughly agitated during use, thus ensuring
that the particle content is maintained in suspension and is within the
specified limits.
(3) The ink may be applied by flowing on, spraying or immersion. When the
ink is applied during magnetization this is known as (simultaneous
inking) or (wet continuous technique).When the ink is applied after
magnetization the process is known as the (residual technique).
(4) When using the simultaneous (wet continuous) inking technique, inking
must start before the current is switched on and be stopped before the
current is switched off.
(5) When using the residual technique the ink must be applied after the
part is magnetized.Alternating current must not be used to magnetise
parts for residual techniques.
D. Current requirements
Because the different makes of magnetic particle machines have various

types of current output, the amperages read from the machine may not be of
the same meter scaling as those established by Rolls-Royce.
Machines may have one or more of the following output amperage forms:
(1) Alternating current (AC).
(2) Half-wave rectified A.C. (HWRAC).
(3) Full-wave rectified A.C. (FWRAC).
(4) Smoothed Full-wave rectified A.C. (Three phase FWRAC) giving a wave
form similar to that obtained from a battery.
For the scaling of the output ammeters, refer to Fig 70-00-00-990-201-003
All current values given in this and the Engine Manual are RMS values and
require no conversion if ammeters are calibrated to 0.7 peak.
Where machine ammeters read average or twice average current, no conversion

is required.

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Where machine ammeters read peak current, the RMS amperage specified in the
Engine Manual needs to be converted to peak amperage by multiplying the RMS
value by 1.4.
When applying the current, it shoud be applied for a period of 2 to 3

seconds in order to magnetise the part.
E. Spiral coil and split threading bar
Where the spiral coil or split threading bar is specified in the Engine
Manual, used normally as a residual techniques, the amperage used should be
the maximum available which should not be less than 1000 amperes HWRAC or
1400 amperes FWRAC unless otherwise specified in the Engine Manual
F. Coil
Where the solenoid coil technique is used as the magnetising method, the
current values given in the Engine Manual are for 406 mm (16 in.) diameter
multi-wound coil. If other diameter coils are used, the current necessary
for the coil is calculated using formula that follows.
NI = 430 r (in.)
or
NI = 170 r (cm.)
Where N = number of turns in the coil
I = Amperes A.C. r.m.s.
r = radius of coil
G. De-magnetisation
In all instances the part should be de-magnetised before and after magnetic
particle inspection as follows;
(1) Insert the part in the de-magnetisation coil.
(2) Switch on the coil.
(3) Pass the part through the coil.
(4) Withdraw the part to a minimum distance of 1,5m ( 5 feet)..
(5) Switch off the current.
(6) Check that the part is magnetised.
De-magnetisation is also necessary between two magnetisations of the same

part, if the second, which is usually at right-angles to the first, is
insufficient to overcome the residual field.
A de-magnetisation part should not be brought nearer than 1,5m.(5 feet) to

an energised de-magnetiser coil or magnetising equipment.

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Small parts can be de-magnetised on a non-magnetic tray or basket in a

single layer. The optimum strength of the de-magnetising field at the
position of the part under treatment is 6,67kA/m.(85 oersteds) or greater.
The minimum acceptable field strength is 5,57kA/m.(70 oersteds).
De-magnetisation of engine parts should be checked with a magnetic field

indicator similar to the Magnaflux pocket type. A needle deflection of two
divisions measured at any position on the part is the maximum acceptable;
three divisions is acceptable on assemblies.
Should accurate quantitative measurement be required or where it is

required to detect very low field strengths an instrument of the Forster
Tangential Field Strength Meter type should be used, being calibrated and
applied in strict accordance with the manufacturer's instructions.
H. Flux indicators
The use of OMat 612 magnetic particle inspection flux indicators are
recommended to establish the direction of magnetic field and in some
instances the minimum strength of the applied magnetic field for the
effective magnetisation of parts. They are particulary useful for
establishing the magnetic values to be used when magnetic flux flow
magnetising methods are being used.
I. Paint/Coatings
As a general rule, all coatings need to be removed before a part is

Magnetic particle inspected, as coatings reduce the sensitivity of the
inspection. However, if the coating is less than 0,025 mm (0.001 in) thick
and non magnetic, then the part can be Magnetic particle inspected with the
coating in place.
Current Flow (CF) techniques are not recommended on parts with a none
conductive coating, as arcing can occur where the coating is damaged. In
this instance the coating needs to be removed to ensure good electrical
contact with the machine pads.
J. Contact pads
To ensure good contact and to prevent arcing or burning, Current Flow (CF)
contact pads shall have a copper or brass braid pad backed by neoprene
rubber to maximise the contact area on the part.

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K. Inspection
CAUTION: 125 WATT 'SELF FILTERED BULB' ULTRA-VIOLET LAMPS ARE NOT ACCEPTABLE
FOR USE ON ROLLS-ROYCE ENGINE PARTS. ULTRA-VIOLET LIGHTS MUST HAVE
SEPARATE WOODS FILTER AND TYPICALLY USE A 100 WATT MERCURY VAPOUR
PRE-FOCUSED BULB.
Inspection will normally be carried out away from the machine, when moving
an inked part and before to inspection, handle it with care to prevent
smudging. The inspection can if required be carried out on the machine.
For general inspection a low power magnification x2 is normally used. For

detailed inspection x5 to x10 magnification is used. Doubtful indications
should be rechecked at x15 magnification.
L. Pre-cleaning
The parts should be pre-cleaned bevore to MPI as follows:
CAUTION: BEARINGS MUST BE DEGREASED IN KEROSENE ONLY
(1) Wash all bearings in OMat 101 kerosine or OMat 1/260 odourless kerosine
only.
(2) Degrease all other parts, refer to TASK 70-00-00-100-102 (O.P.102) or

TASK 70-00-00-100-101 (O.P.101).
M. Post-cleaning and protection
The parts should be post-cleaned and protected as follows:
CAUTION: BEARINGS MUST BE DEGREASED IN KEROSENE ONLY
(1) Wash all bearings in OMat 101 kerosine or OMat 1/260 odourless kerosine
only.
(2) Degrease all other parts, refer to TASK 70-00-00-100-102 (O.P.102) or

TASK 70-00-00-100-101 (O.P.101).
(3) Protect the parts by applying temporary rust preventive, see TASK
70-00-00-300-340 (O.P.340).Inhibit bearings, as described in TASK
70-00-00-100-112 (O.P.112).
SUBTASK 70-00-00-240-201-001
6. Inspection Procedure - Current Flow
A. Refer to SUBTASK 70-00-00-860-201-053 for safety precautions and SUBTASK

70-00-00-860-201-054 for general information.

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B. Application
(1) This method is used to detect defects which are approximately parallel
to the direction of the current flow, i.e. Longitudinal (L) and Radial
(R) in tubular or bar parts and Circumferential (C) in circular parts
Fig. 70-00-00-990-201-004.

C. Procedure
(1) Pre-clean the part.
(2) De-magnetize the part.
CAUTION: TO PREVENT ARCING AND CONSEQUENT DAMAGE TO THE PART. GOOD CONTACT
MUST BE MADE BETWEEN THE TERMINAL PADS AND THE P.ART
(3) Position the part on the magnetizing machine.
(4) Apply detecting ink (see SUBTASK 70-00-00-860-201-052), this must be in

a thoroughly agitated condition, and pass the required current through
the part.
(5) Inspect the part, in the machine where possible. Parts may require
rotating to inspect the blind side and to apply more detection ink.
(6) If the part is diametrically clamped rotate it through 90 degrees and

repeat paragraphs (4) and (5).
(7) Remove the part from the machine and allow to drain. When moving an
inked part and bevore to inspection, handle it with care to prevent
smudging.
(8) Inspect the part.
(10) Post clean and protect the part.
SUBTASK 70-00-00-240-201-002
7. Inspection Procedure - Threading Bar

B. Application
(1) This method is used to detect Longitudinal (L) and Radial (R) defects
in tubular parts and circular parts, that can be threaded over a single
conducting bar, through which the current required to create a magnetic
field is passed. .
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(2) Where an offset threading bar technique is used, a number of separate

magnetizations will be required at equi-spaced points to ensure
complete and equal coverage of each portion of the circumference, ink
being applied at each shot, Fig 70-00-00-990-201-B05.
(3) Threading cable, energised from the machine may be used for testing
areas around attachment holes, Fig 70-00-00-990-201-B05.
C. Processing
(1) Pre-clean the part
(3) Pass a threading bar through the bore of the part and mount on to the
MPI machine.
(4) When required, support the part on non-conducting blocks, spacers or

rollers so that the threading bar is positioned centrally in the bore
of the part.
(5) Apply detecting ink using the simultaneous (wet continuous) technique
and magnetize the part by passing the required current through the
threading bar.Magnetizing should be accomplished in several shots.
The parts should be rotated during the operation to expose the areas
resting on the blocks, spacers or rollers.
When moving an inked part and bevore inspection, handle it with care to
avoid smudging.
(6) Allow the part to drain.
(8) De-magnetize the part. .
SUBTASK 70-00-00-240-201-003
8. Inspection Procedure - Multiple Threading Bar/Split Coil

B. Application
(1) This method is used to detect Longitudinal (L) and Radial (R) defects
in circular and tubular parts and is used only with HWRAC or FWRAC OR
DC.
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(2) The equipment for this method, sometimes known as the "knife" method or
"split coil", is illustrated in Fig.70-00-00-990-201-006.
C. Processing
(1) Pre-clean the parts.

(3) Place the part so that it is located centrally on the magnetizing

machine.
(4) Magnetize the part, whilst it is rotating.
(5) Remove the part from the machine and immerse it for a minimum period of
10 seconds in the detecting ink (see SUBTASK 70-00-00-860-201-052).
NOTE: Paragraphs (4) and (5) may be carried out using simultaneous
(wet continuous) inking.
(6) Allow the part to drain. When moving an inked part and before
inspection, handle it with care to prevent smudging.
SUBTASK 70-00-00-240-201-004
9. Inspection Procedure - Flat Spiral Coil

B. Application
(1) This method is used to detect circumferential defects in discs or

similar shaped parts.
(2) The equipment consists of a close-wound flat coil, see

Fig.70-00-00-990-201-007, the diameter of which must be at least 4 in.
greater than the diameter of the part being magnetized.
(3) The coil is energized by DC half or full wave rectified AC.
C. Processing

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(3) Locate the part centrally on the coil.
NOTE: Parts featuring stub-shafts can be magnetized by fitting the

shaft portion into the bore of the coil.
(4) Magnetize the part using the current specified.
(5) Immerse the part for a minimum of 10 seconds in the detecting ink (see
SUBTASK 70-00-00-860-210-052).
NOTE: Paragraphs (3) and (4) may be carried out using simultaneous
(wet continuous) inking.
(6) Mount the part on a fixture for inspection.
(9) Repeat paragraphs (3) to (8) with the reverse face nearest to the coil
during magnetization.
(10) Post clean and protect the parts.
SUBTASK 70-00-00-240-201-005
10.Inspection Procedure - Solenoid Coil

B. Application
(1) This method is used to detect Circumferential (C) or Transverse (T)

defects as shown in Fig.70-00-00-990-201-009. The method gives
adequate lengthwise magnetization of parts having a ratio of length to
diameter (L to D) greater than 3 : 1.
Only the portion of the part which lies within one radius of the coil
centre line is magnetised, repeat magnetisations and inspections are
necessary when inspecting long parts.
Where the part L to D ratio is less than 3 : 1, but greater than 2 : 1

the magnetizing force can be increased to twice that specified. Below 2
: 1 extenders must be used to increase the L to D ratio or magnetic
flow ( M.F.) can be used. M.F is preferred to the coil method on parts
where the length to diameter ratio is less than 3 : 1.

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C. Processing
(2) De-magnetize the part

(3) Position the part within the coil.
(4) Magnetize the part using the current specified in the Engine Manual and
A.C. or HWRAC or D.C. using the simultaneous (wet continuous) inking
technique.
(5) Remove the part from the coil or the coil from the part, whichever is
applicable.When moving an inked part, before inspection, handle with
care to prevent smudging.
(7) Repeat paragraphs (4) to (6) along the length of the part if the part
is no longer than twice the coil radius. If it is not practicle to
remove the part for inspection, the part can be inspected on the
machine.
(8) De-magnetise the part
SUBTASK 70-00-00-240-201-006
11.Inspection Procedure - Magnetic Flow

B. Application
(1) This method is used to detect Transverse (T) defects as shown on Fig
70-00-00-990-201-010. The method is normally used when the part has a L
to D ratio less than 3 : 1, but can be used on parts up to 0.3 m (12
in) long.
The copper or brass gauze pads should be removed from the headstocks,
enabling the part to be in direct contact with the headstocks to allow
the maximum transmission of magnetic field.
As no electric current is passed through the part there is no danger

from arcing at the contacts.

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(2) Where magnetic flow is not available, the coil method see SUBTASK
70-00-00-240-201-005 may be used as an alternative. When this is
applied and the L to D ratio is less than 3 : 1 but greater than 2 : 1
the magneticising force can be increased to twice that specified. Below
2:1 extenders must be used to increase the L to D ratio.
C. Processing
(1) Pre-clean the part..
(3) Position the part longitudinally between the pads of the machine.
(4) Adjust the machine whilst applying detecting ink, see SUBTASK
70-00-00-860-201-052, to give the maximum magnetic flow available
consistent with the minimum background build-up. The use of flux
indicators is recommended to confirm magnetisation. Switch off the
energizing current.
NOTE: If an excessive build-up of particles occurs adjacent to the

magnetic poles the particles may be removed by washing and
detecting fluid re-applied.
(5) Remove the part from the machine.
(6) Allow the part to drain.When moving an inked part before inspection,
handle it with care to prevent smudging.
SUBTASK 70-00-00-240-201-007
12.Inspection Procedure - Current Induction

B. Application
(1) This method is used to detect Circumferential (C) defects in annular

parts and is particularly suited to rings of a less rigid nature where
other methods are less satisfactory. It is not recommended for parts
such as compressor discs where the radial dimension is far in excess of
the sectional thickness.

Page 15
R Oct. 1/02
TSD
(2) The method is derived from the principle of the transformer. The
primary windings are wound onto a laminated iron core which can be
broken in such a manner that it can be threaded through the part to be
tested, Fig.70-00-00-990-201-011. Application of current to the
primary windings energizes the laminated core, which will in turn
induce a current into the ring, it is this induced current which

creates the magnetic field.
(3) The current specified in the Engine Manual is the current required to
be induced in the ring. this induced current must be measured by means
of a clip on or detachable meter.
C. Processing
(1) Wash all bearings in OMat 101 kerosine only.
(4) Position the part on the machine.
(5) Apply detecting ink, see SUBTASK 70-00-00-860-201-052, magnetize the

part using A.C. with the simultaneous (wet continuous) technique, Use a
clip on or detachable meter to ensure that the recommended current is
induced.
(6) Remove the part from the machine.
(7) Allow the part to drain. When moving an inked part before inspection,
handle it with care to prevent smudging.

Page 16
R Oct. 1/02
TSD
Standard functional test pieces for circular magnetism

R Fig 70-00-00-990-201-001-001

Page 17
R Jun. 1/02
TSD
Standard functional test pieces for curcular magnetism

R Fig 70-00-00-990-201-001-002

Page 18
R Jun. 1/02
TSD
Functional test piece for longitudinal magnetism

Fig.70-00-00-990-201-002

Page 19
Apr. 5/99
TSD
Functional test piece for longitudinal amperage

R Fig 70-00-00-990-201-003

Page 20
R Jun. 1/02
TSD
Current flow
Fig.70-00-00-990-201-004

Page 21
Apr. 5/99
TSD
Threading bar
Fig.70-00-00-990-201-A05

Page 22
Apr. 5/99
TSD
Threading bar
Fig.70-00-00-990-201-B05

Page 23
Apr. 5/99
TSD
Multiple threading bar/split cowl - longitudinal and radial defects

Fig.70-00-00-990-201-006

Page 24
Apr. 5/99
TSD
Flat spiral coil - circumferential and radial defects

Fig.70-00-00-990-201-007

Page 25
Apr. 5/99
TSD
Types of solenoid coil

R Fig 70-00-00-990-201-008

Page 26
R Jun. 1/02
TSD
Permanent solenoid coil with built-in steel extenders -

transverse defects
Fig.70-00-00-990-201-009

Page 27
Apr. 5/99
TSD
Magnetic flow - circumferential defects

Fig.70-00-00-990-201-010

Page 28
Apr. 5/99
TSD
Current induction - circumferential defects

Fig.70-00-00-990-201-011

Page 29/30
Apr. 5/99
TSD
RED DYE PENETRANT INSPECTION

TASK 70-00-00-200-203 Overhaul Process 203 - Red Dye Penetrant

Inspection
1. Procedure
This process has been deleted, wherever this process is called up in an Engine
Manual use Overhaul Process 213 (TASK 70-00-00-200-213), Water-Washable
Fluorescent Penetrant Inspection as:
Subtask 70-00-00-230-203-001 use Subtask 70-00-00-230-213-001
Subtask 70-00-00-230-203-002 use Subtask 70-00-00-230-213-002

Page 1/2
Dec. 1/95
TSD
ELECTROLYTIC ETCHING OF STEEL PARTS

TASK 70-00-00-200-205 Overhaul Process 205 - Electrolytic

Etching of Steel Parts
SUBTASK 70-00-00-860-205-051
1. Materials Used in the Overhaul Process
OMat 110 Sulphuric acid (H2SO4)

OMat 119 Sodium carbonate (Na2CO3)
OMat 125 Nitric acid (HNO3)
OMat 172 Hydrofluoric acid (HF)
OMat 1066 Lubricating oil (D.E.R.D/O)
SUBTASK 70-00-00-860-205-052
2. Materials Used in the Make-up and Control of Solutions
OMat 157 Sodium hydroxide (NaOH)

OMat 1/74 Indicator
SUBTASK 70-00-00-180-205-001
3. Make-up and Control of Etching Solution
A. Refer to SUBTASK 70-00-00-860-205-051 and SUBTASK 70-00-00-860-205-052 for

the list of materials used in this process.
B. Composition.
R OMat 110 sulphuric acid 880 to 920 g./litre.
The solution can be made-up by adding 1 volume of sulphuric acid (S.G.

1.84) to 1 volume of water, but as this method develops sufficient heat to
cause the solution to boil, it is recommended that solution of the correct
strength be purchased, together with a supply of sulphuric acid (S.G. 1.84)
for making additions. Tap water can be used if the chloride content does
not exceed 0.15 g./litre.

Page 1
R Nov. 1/03
TSD
The etching solution must be contained in a lead-lined tank fitted with

fume extraction and a cooling water jacket maintained at a temperature of
10 to 20 deg.C. (50 to 68 deg.F.). The solution must be agitated by means
of clean, dry, oil-free compressed air. The sides of the tank form one
pole of the electrical circuit when components are etched in the horizontal
position or singly in the vertical position. Auxiliary cathodes may also

be necessary to achieve a satisfactory etch on components of complex
geometry.
C. Analyse the solution.
(1) The solution should be analysed frequently, twice daily if in continual

use, to ensure that the acid content is maintained within the required
range.
(2) The solution absorbs moisture from the atmosphere, therefore, if it has
not been in recent use, it must be analysed and its strength corrected
before parts are etched.
Transfer, by using a pipette, 20 ml. of sample into a standard 200 ml.

flask.
Dilute to the mark with distilled water and shake well.
Transfer, by using a pipette, 20 ml. of this diluted solution into a

beaker.
Add a few drops of OMat 1/74 indicator and titrate with N sodium
hydroxide (prepared from OMat 157 sodium hydroxide) to a yellow end
point; the following will then apply:
1 ml. N. sodium hydroxide = 0.049 g. sulphuric acid
therefore ml. N. sodium hydroxide x 0.049 x 500 = g./litre sulphuric

acid
To calculate the amount of addition, multiply the g./litre low by the

capacity of the tank (in Imperial gallons) and divide the result by
1803.2 to give the number of Imperial gallons of sulphuric acid (S.G.
1.84).
SUBTASK 70-00-00-180-205-002
4. Make-up and Control of Neutralizing Solution
A. Refer to SUBTASK 70-00-00-860-205-051 for the list of materials used in

this process.

Page 2
Dec. 1/95
TSD
B. Composition.
The solution is an aqueous one containing 70 g./litre OMat 119 sodium

carbonate.
C. Control
To ensure that the residual acid on parts is effectively neutralized, the

solution should be discarded and replaced frequently with new solution.
SUBTASK 70-00-00-180-205-003
5. Make-up and Control of Dewatering Oil
Refer to TASK 70-00-00-300-340 (O.P.340) for details and method of control.
SUBTASK 70-00-00-180-205-004
6. Make-up and Control of Desmutting Solution for Nickel-base Materials
A. Refer to SUBTASK 70-00-00-860-205-051 for the list of materials used in

this process.
B. Composition.
OMat 172 hydrofluoric acid 50 g./litre
OMat 125 nitric acid HNO3 200 g./litre.
C. Make-up for 5 litres
To approximately 2.5 litres of water carefully add 1010 ml. of OMat 125
R nitric acid (S.G. 1.42) and then 550 ml. of hydrofluoric acid 40 percent HF
W/W (OMat 172 hydrofluoric acid). Gently stir the solution whilst making
additions. Finally, by adding water, adjust the volume to 5 litres.
The solution should be contained in a plastic tank and maintained at 15 to

25 deg.C. (59 to 77 deg.F.).
D. Analysis
No analysis is necessary, the solution is discarded when it ceases to be

effective.

Page 3
R Nov. 1/03
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SUBTASK 70-00-00-860-205-053
The health and safety data given are general guidelines in use at Rolls-Royce,
it is the responsibility of the operator/user to obtain detailed health and

safety data for the materials in use and to refer to local regulations to
ensure safe working practice.
Refer to WARNINGS 1 through 5 which follow.
WARNING: 1. PROTECTIVE CLOTHING AND GOGGLES MUST BE WORN TO PREVENT SOLUTION

CONTACTING EYES OR SKIN
2. RUBBER GLOVES MUST BE WORN, THESE MUST BE CHECKED REGULARLY FOR

PIN HOLES AND IMMEDIATELY REPLACED IF DEFECTIVE.
3. EYE SPLASHES MUST BE TREATED IMMEDIATELY BY PROLONGED WATER

IRRIGATION OF THE EYES, FROM THE EYE-WASH BOTTLES PROVIDED, AND
REPORT FOR IMMEDIATE MEDICAL TREATMENT.
4. SKIN SPLASHES MUST BE RINSED WITH COPIOUS AMOUNTS OF CLEAN,

RUNNING WATER.
5. ALL BURNS, HOWEVER SLIGHT, MUST BE TREATED AT THE NEAREST

SURGERY OR FIRST-AID POST. THE SURGERY OR FIRST-AID POST MUST
BE TOLD WHICH SOLUTION (I.E. THE ACIDS INVOLVED) CAUSED THE
BURN, THIS APPLIES PARTICULARLY WHEN HYDROFLUORIC ACID IS A
CONSTITUENT.
6. SAFETY NOTICES MUST BE PLACED IN A CONSPICUOUS PLACE.
SUBTASK 70-00-00-860-205-054
8. General
CAUTION: 1. THIS PROCESS MUST BE CAREFULLY CONTROLLED AND MUST ONLY BE USED
WHEN SPECIFIED IN THE ENGINE MANUAL FOR THE PARTICULAR PART.
2. TOOLING FOR MAJOR ROTATING PARTS DETAILED IN THE ENGINE MANUAL,

MUST NOT BE LOCATED ON THIN SECTIONS WHICH MAY DEFLECT AND
IMPART BENDING STRESSES CAPABLE OF CAUSING EMBRITTLEMENT
CRACKING DURING THE ELECTROLYTIC ETCHING PROCESS.
Electrolytic etching produces an even matt surface which facilitates

inspection by revealing crack and surface defects. The process is sometimes
used as a preparation for electroplating to facilitate adhesion. The process
is applied in two ways:
Process Etch Gears and Case Hardened Parts (SUBTASK 70-00-00-110-205-001).

Page 4
Dec. 1/95
TSD
Process Etch Major Rotating Parts (SUBTASK 70-00-00-110-205-002).
SUBTASK 70-00-00-110-205-001
9. Process Etch Gears and Case Hardened Parts

The parts to be etched are suspended to form the anode in a tank containing
the etching solution. The tank itself is usually used as the cathode but a
specially shaped cathode may sometimes be required. An electric current is
passed through the part causing metal to be removed from it.
A. Refer to SUBTASK 70-00-00-860-205-051, SUBTASK 70-00-00-860-205-053 and

SUBTASK 70-00-00-860-205-054 for Safety Precautions, General and list of
materials used in this process.
B. Mount the parts on to suspenders as described in the Engine Manual.
C. Vapour degrease the parts, refer to TASK 70-00-00-100-101, (O.P.101)

SUBTASK 70-00-00-110-101-001 or hot aqueous degrease as described in TASK
70-00-00-100-118 (O.P.118).
D. Caustic clean the parts, refer to TASK 70-00-00-100-105 (O.P.105).
E. Maintain the temperature of the etching solution at between 10 and 20

deg.C. (50 and 68 deg.F.). In hot climates a temperature of 30 to 35
deg.C. (86 to 95 deg.F.) may be used, but at this temperature the etching
time must be reduced by half.
F. Set the voltage control to give an open circuit voltage of 10 volts.
G. Suspend the parts from the busbar so that they are immersed in the
solution; ensure a good contact between busbar and suspender.
H. Switch on the electrical supply anodically. When etching commences there

will be a drop in voltage proportional to the current flow through the
part; adjustment for this drop in voltage must not be made.
I. Etch the parts for the time detailed in the Engine Manual. Refer to
paragraph E. of this SUBTASK 70-00-00-110-205-001.
J. Wash the parts in clean, cold running water, remove them from the
suspenders and suspend them on a clean rope or suitable device ensuring
that the etched surface is not handled.
K. Wash the parts again, in clean, cold, running water.
L. Immerse the parts in neutralizing solution, consisting of the OMat 119

sodium carbonate in tap water at 15 to 25 deg.C. (59 to 77 deg.F.). Refer
to SUBTASK 70-00-00-180-205-002.

Page 5
Dec. 1/95
TSD
M. Wash the parts thoroughly in clean, cold, running water, using an air/water
gun.
N. Immerse the parts in an approved dewatering oil, refer to TASK

70-00-00-300-340 (O.P.340) maintained at a temperature of 105 to 110 deg.C.
(221 to 230 deg.F.).

O. Remove the parts and allow them to drain.
CAUTION: ALL PARTS MUST BE DE-EMBRITTLED AFTER ETCHING.
P. De-embrittle the parts by heating for 2 hours in an oil bath at a

temperature of 120 to 140 deg.C. (248 to 284 deg.F.). The recommended oil
is OMat 1066 lubricating oil).
SUBTASK 70-00-00-110-205-002
10.Process Etch Major Rotating Parts
A. Refer to SUBTASK 70-00-00-860-205-051, SUBTASK 70-00-00-860-205-053 and

SUBTASK 70-00-00-860-205-054 for Safety Precautions, General and list of
materials used in this process.
B. Vapour degrease the parts, refer to TASK 70-00-00-100-101, (O.P.101)

SUBTASK 70-00-00-110-101-001 or hot aqueous degrease, refer to TASK
70-00-00-100-118 (O.P.118).
CAUTION: STRESS RELIEVING MUST BE EFFECTED ON STEEL PARTS WHICH EXCEED A

TENSILE STRENGTH OF 100 MN/SQ.M. (65 TON F/SQ.IN.) OR HARDNESS 302
HB OR 310 HV OR MORE, TO AVOID CRACKING FROM HYDROGEN EMBRITTLEMENT.
C. Stress relieve the parts by heating in a hot air oven at 290 to 310 deg.C.
(554 to 590 deg.F.) if required by the Engine Manual, and allow to cool.
D. Mount the parts on to suspenders as described in the Engine Manual.
E. Vapour degrease the parts, refer to TASK 70-00-00-100-101 (O.P.101) SUBTASK

70-00-00-110-101-001 or hot aqueous degrease, refer to TASK
70-00-00-100-118 (O.P.118)
F. Caustic clean the parts, refer to (TASK 70-00-00-100-105) (O.P.105).
G. Maintain the temperature of the etching solution at between 10 and 20

deg.C. (50 and 68 deg.F.). In hot climates a temperature of 30 to 35
deg.C. (86 to 95 deg.F.) may be used, but at this temperature the etching
time must be reduced by half.
H. Set the voltage control to given an open circuit voltage of 10 volts.
I. Suspend, from the busbar, the parts to be etched so that they are immersed
in the solution; ensure a good contact between busbar and suspender.
Page 6
Dec. 1/95
TSD
J. Switch on the electrical supply, either cathodically or anodically

whichever is required.
(1) The actual cycle for a particular part is given in the Engine Manual.
The cycle can differ from that given in SUBTASK 70-00-00-110-205-001 by
the current being reversed from anodic to cathodic on some parts to
assist cleaning.
(2) When etching commences there will be a drop in voltage proportional to

the current flow through the part; adjustment for this drop in voltage
must not be made.
K. Etch the parts according to the cycle required by the Engine Manual. Refer
to paragraph G. of this SUBTASK 70-00-00-110-205-002.
L. Wash the parts in clean, cold running water, remove them from the
suspenders and suspend them on a clean rope, or suitable device, ensuring
that the etched surface is not handled.
M. Wash the parts again, in clean, cold running water.
N. Immerse the parts in neutralizing solution, consisting of the (OMat 119)

sodium carbonate in tap water at 15 to 25 deg.C. (59 to 77 deg.F.). Refer
to SUBTASK 70-00-00-180-205-002.
O. Wash the parts thoroughly in clean, cold, running water, using an air/water
gun.
P. Immerse the parts in clean, boiling water, for sufficient time for them to
achieve the temperature of the water. It is permissible to dry-off parts
from an immersion in water at 85 deg.C. (185 deg.F.) or above if difficulty
in maintaining boiling temperature is experienced.
Q. Remove the entrapped water, by means of a clean, dry, air blast, while the
parts are still hot.
CAUTION: DE-EMBRITTLEMENT MUST BE EFFECTED ON STEEL PARTS WHICH EXCEED A

TENSILE STRENGTH OF 1000 MN/SQ.M. (65 TON F/SQ.IN.) OR HARDNESS 302
HB OR 310 HV OR MORE TO AVOID CRACKING FROM HYDROGEN EMBRITTLEMENT.
R. De-embrittle the parts by heating for 2 hours in a hot air oven at 190 to
210 deg.C. (374 to 410 deg.F.), if required by the Engine Manual. It is
permissible, for convenience, to use a temperature of 300 deg.C. (572
deg.F.) for de-embrittlement. If this temperature is used the operator
must be prepared to accept a certain amount of surface discolouration
during inspection.

Page 7/8
Dec. 1/95
TSD
ELECTROPOLISHING
TASK 70-00-00-200-208 Overhaul Process 208 - Electropolishing
SUBTASK 70-00-00-860-208-051
OMat 7/40 Stopping-off lacquer, erosion resistant varnish, red

OMat 7/102 Thinners, high flash cellulose
OMat 1033A Compressor oil
SUBTASK 70-00-00-860-208-052
2. Materials Used in the Make-up and Control of Solutions
OMat 110 Sulphuric acid (H2SO4)

OMat 111 Chromium trioxide (CrO3)
OMat 117 Phosphoric acid (H3PO4)
OMat 125 Nitric acid (HNO3)
OMat 1/88 Potassium permanganate (KMnO4)
OMat 1/94 Ferrous ammonium sulphate (FeSO4(NH4)2SO4 (H2O)6)
OMat 1/157 Sulphuric acid (H2SO4)
SUBTASK 70-00-00-180-208-001
3. Make-up and control of Nimonic Electropolishing Solution

lists of materials used in the process
B. Composition
OMat 117 phosphoric acid - 790 to 940 g./litre
OMat 110 sulphuric acid - 295 to 365 g./litre
50 litres of solution are made up as follows:

Page 1
Dec. 1/95
TSD
To 4.75 litres of water add carefully, with constant stirring, first 35.0
litres of phosphoric acid (S.G. 1.65) and then 10,25 litres of sulphuric
acid (S.G. 1.84).
NOTE: The strength of the solution is maintained by additions of the

appropriate acids based on analysis results. To assist in

maintaining the acid concentration and to avoid the necessity of
making large additions on the results of analysis it is advantageous
to make small additions of both acids at frequent intervals during
the solution life. As a guide to the size of such additions a vat
of 336 litres capacity requires additions of 1 litre of phosphoric
acid (S.G. 1.65) and 540 ml. of sulphuric acid (S.G. 1.84) after
each 155 square decimetres of blade surface polished.
The entire solution should be discarded when a total of 8633 amp. minutes
per litre have been polished.
C. Analyse the Nimonic electropolishing solution
(1) Take 25 ml. of sample in a standard flask and transfer it to a 250 ml.
standard flask.
(2) Wash out the 25 ml. flask well with distilled water and add the
washings to the 250 ml. flask.
(3) Make up to 250 ml. with distilled water and shake well.
(4) Pipette 20 ml. of this diluted solution into a suitable beaker and
titrate electrometrically with N sodium hydroxide solution prepared
from OMat 157 sodium hydroxide. This must be done by plotting a graph
of pH value against ml. of sodium hydroxide as follows:
(5) Record the pH value each time an addition is made in accordance with
the following table, making small additions of N sodium hydroxide as
the end points are approached. The results are plotted in a graph
(Fig.70-00-00-990-208-B01) and, by drawing tangents to the steep
portions of the curve, the mid-points of the neutralization zones are
estimated to the nearest 0.05 ml. The first end point (T1) represents
the amount of N sodium hydroxide equivalent to all the sulphuric acid
and one third of the phosphoric acid present in the sample.
The second end point (T2) represents the amount of the N sodium
hydroxide equivalent to all the sulphuric acid and two-thirds of the
phosphoric acid present in the sample.
1 ml. N sodium hydroxide = 0.098 g. phosphoric acid
1 ml. N sodium hydroxide = 0.049 g. sulphuric acid
Therefore (T2 - T1) x 0.098 x 1000 divided by (20 x 25/250) = g./litre

sulphuric acid

Page 2
Dec. 1/95
TSD
i.e. (T2 - T1) x 49 = g./litre phosphoric acid
and (2 x T1) - T2 x 0.049 x 1000 divided by (20 x 25/250) = g./litre

sulphuric acid
i.e. 2T - T2 x 24.5 = g./litre sulphuric acid

An example of electrometric titration is shown in the accompanying

table and graph. Refer to Fig.70-00-00-990-208-A01
By reference to the graph, it will be seen that T1 = 32 ml. and T2 = 49

ml.
Therefore T2 - T1 x 49 = 17 x 49 = 833 g./litre phosphoric acid and (2

x T1) - T2 x 24.5 = 15 x 24.5 = 367.5 g./litre sulphuric acid
Additions of the acids are calculated as follows:
Sulphuric acid - Multiply g./litre low by the capacity of the vat (in
litres) and divide the result by 1803 to give litres of
sulphuric acid (s.G. 1.84).
Phosphoric acid - Multiply g./litre low by the capacity of the vat (in
litres) and divide the result by 1336 to give litres of
phosphoric acid (S.G. 1.65).
SUBTASK 70-00-00-180-208-002
4. Make-up and Control of Hot Nitric Acid Solution for De-smutting Nimonic 95A or
Higher Numbers

lists of materials used in this process
B. Composition
Nitric acid - 160 to 180 g./litre
The solution is made up by carefully adding, with constant stirring, 18

parts by volume of OMat 125 nitric acid HNO3 (S.G. 1.42) to 82 parts by
volume of water.
Maintain the solution, during processing, at a temperature of 65 to 70

deg.C. (149 to 158 deg.F.)
Analysis is not required; the solution is discarded when it ceases to

function in the given period.

Page 3
Dec. 1/95
TSD
SUBTASK 70-00-00-180-208-003
5. Make-up and Control of Cold Nitric Acid for Cleaning Nimonics of Lower Numbers
than 95A

B. Composition
Nitric acid - 396 g./litre
The solution is made-up by carefully adding, with constant stirring, 40

parts by volume of OMat 125 nitric acid HNO3 (S.G. 1.42) to 60 parts by
volume of water. It is used at room temperature. Analysis is not
required; the solution is discarded when it ceases to function.
SUBTASK 70-00-00-180-208-004
6. Make-up and Control of Aluminium Electropolishing Solution

B. Composition
OMat 117 phosphoric acid - 1100 to 1250 g./litre
OMat 111 chromium trioxide - 150 to 180 g./litre
50 litres of solution are made-up as follows:
Dissolve 8,25 kg. of chromium trioxide in the smallest possible quantity of

water and add 44 litres of phosphoric acid (S.G. 1.65).
C. Analyse the aluminium electropolishing solution
(1) Estimation of chromium trioxide
By means of a standard flask measure 25 ml. of sample into a 250 ml.

standard flask.
Rinse the small flask with distilled water and add the washings to the
bulk.
Dilute to 250 ml. with distilled water and shake well.
Pipette 5 ml. of this diluted solution into a suitable beaker and add
approx. 100 ml. of distilled water and 10 ml. of 50 per cent, sulphuric
acid (prepared from OMat 1/157 sulphuric acid)

Page 4
Dec. 1/95
TSD
From a burette run in N/10 ferrous ammonium sulphate (FAS), (prepared

from OMat 1/94 ferrous ammonium sulphate) until the mixture turns blue,
noting the amount of the solution used.
Back titrate with N/10 potassium permanganate solution (prepared from

OMat 1/88 potassium permanganate) until a pink colour is obtained.
ml. of FAS solution - ml. potassium permanganate = ml. of FAS solution

which are equivalent to the chromium trioxide in the sample (T1).
Carry out a blank estimation as follows:
Run 10 ml. of N/10 FAS solution into a suitable beaker and add approx
100 ml. of distilled water and 10 ml. of 50 per cent. sulphuric acid.
Titrate with N/10 potassium permanganate solution to a pink end point.
The number of ml. of potassium permanganate solution is T2. The

chromium trioxide content of the sample is calculated as follows:
1 ml. N/10 FAS solution = 0,00333 g. chromium trioxide
Therefore T1 x T2/10 x 6.66 = g./litre chromium trioxide
(2) Estimation of phosphoric acid
Using a standard flask measure 25 ml. of sample into a 25 ml. standard

flask.
Rinse the small flask with distilled water and add the washings to the
bulk.
Dilute to 250 ml. with distilled water and shake well.
Pipette 20 ml. of this diluted solution into a suitable beaker and

titrate electrometrically with N sodium hydroxide (prepared from OMat
157 sodium hydroxide) as in SUBTASK 70-00-00-180-208-001 Nimonic
Electropolishing Solution.
Obtain the two end points T1 and T2 from the graph

(Fig.70-00-00-990-208-B01).
Calculate the phosphoric acid content as follows:
T1 + (T2/2) all divided by 2 = A ml.
Calculate the amount of N sodium hydroxide used by the chromium

trioxide from the g./litre figure obtained in the first analysis as
follows:
(g./litre chromium trioxide divided by 1000) x (20/250) x 25 x 10 =

g./litre chromium trioxide divided by 50.

Page 5
Dec. 1/95
TSD
Then (A-B) x 49 = g./litre phosphoric acid
(3) Control
NOTE: It is only necessary to analyse the freshly made-up solution in

order to check the make-up.

To maintain solution level, equal volumes of water and
phosphoric acid (S.G. 1.65) are added as required. With a new
solution a potential difference of approx. 15 volts is required
in order to maintain a current density of 2.4 amp. per sq.in.
(37 amp. per sq. dm.). As the bath ages, the increase in
aluminium content causes an increase in viscosity and resistance
which in turn requires an increased potential difference to
maintain the current density. The required amps. will always be
obtained at a potential difference lower than 30 volts during
the first three-quarters of a solution life, then a stage will
be reached when the potential difference required to maintain
correct density will be in excess of 30 volts. At this stage
voltages greater than 30 will produce a current effect, normally
on the trailing edge of the end blade in the jig. This cannot be
tolerated and the volts therefore should be left at 30 during
this period thus allowing the amps. to rise during the polishing
time until they reach the desired figure. It must be realised
that during this period the current density will not be 2.4 amp.
per sq.in. (37 amp. per sq. dm.) during the whole processing
time, but as long as the general appearance of blades is
satisfactory, polishing may continue.
The expected life of the solution is 56 sq. dm. of surface

polished per 4,5 litres when the polishing time is 1 minute.
SUBTASK 70-00-00-180-208-005
7. Make-up and Control of Aluminium/Bronze Electropolishing Solution

B. Composition
OMat 110 sulphuric acid - 90 to 105 g./litre.
OMat 117 phosphoric acid - 900 to 1150 g./litre.
50 litres (10 Imperial gallons) of solution are made-up as follows:
To 7,06 litres of water carefully add, with constant stirring, 40,2 litres
of phosphoric acid (S.G. 1.65) and 2,74 litres of sulphuric acid (S.G.
1.84).

Page 6
Dec. 1/95
TSD
C. Analyse the aluminium/bronze electropolishing solution
(1) The methods of analysis are exactly as detailed under SUBTASK

70-00-00-180-208-001 Nimonic Electropolishing Solution and additions
are calculated in the same way.
CAUTION: IT IS IMPORTANT THAT THE CATHODE PLATES ARE REMOVED FROM THE VAT
AND CLEANED AT FREQUENT INTERVALS (APPROX. EVERY 15 MINUTES WHEN
THE VAT IS IN USE) TO MINIMISE THE AMOUNT OF SPONGY COPPER WHICH
IS SUSPENDED IN THE SOLUTION. IF PRESENT IN LARGE QUANTITIES
THIS COPPER CAN STICK IN THE BLADES CAUSING EXCESSIVE ATTACK IN
LOCAL AREAS.
(2) The level of the solution should be maintained by additions of fresh

solution.
(3) The solution is considered to be exhausted when a total of 870 sq. dm.
of material have been polished for 1 minute in each 4,5 litres of
solution.
SUBTASK 70-00-00-180-208-006
8. Make-up and Control of Steel Electropolishing Solution

B. The composition and methods of analysis and control are exactly as given
under SUBTASK 70-00-00-180-208-004 Aluminium Electropolishing Solution.
C. The expected life of the solution is 232 sq. dm. of surface polished per
4,5 litres when the polishing time is 1 minute.
SUBTASK 70-00-00-860-208-053
The health and safety data given are general guidelines in use at Rolls Royce,

Page 7
Dec. 1/95
TSD
A. Chromic acid solution
In the United Kingdom this process is subject to the Chromium Plating

Regulations 1931 under which there are various duties of Occupiers and of
Persons Employed, in addition to which there is a requirement that every
person employed shall be examined by the Appointed Factory Doctor every 14

days. Over and above the latter it is the duty of the Occupier to arrange
for a responsible person to inspect the hands and forearms of all persons
employed, twice a week.
WARNING: 1. CHROMIC ACID SPRAY IS INJURIOUS IF INHALED, CAUSING ULCERS IN

THE NOSE AND, IN SOME CASES, PERFORATION OF THE NASAL SEPTUM.
CHROMIC ACID SALTS AND SOLUTIONS IN CONTACT WITH THE SKIN MAY
CAUSE CHROME SORES, AND ULCERS MAY BE FORMED IF CHROMIC ACID
GETS INTO CUTS AND ABRASIONS.
2. THE CHROMIC ACID BATH MUST NEVER BE USED UNLESS THE FUME
EXTRACTION PLANT IS IN OPERATION AND FULLY SERVICEABLE.
3. BARRIER CREAM SHOULD BE APPLIED TO THE HANDS AND FOREARMS BEFORE

STARTING WORK.
4. PROTECTIVE CLOTHING MUST BE WORN.
5. SMOKING AND THE CONSUMPTION OF FOOD NEAR THE CHROMIC ACID BATH
ARE PROHIBITED.
6. CUTS OR ABRASIONS WHICH APPEAR NOT TO BE HEALING READILY SHOULD

BE REPORTED WITHOUT DELAY TO THE MEDICAL DEPARTMENT.
7. CHROMIC ACID IS STRONGLY OXIDIZING AND ENTAILS SOME FIRE RISK IF

POSSIBLE SPONTANEOUS COMBUSTION OF ORGANIC MATERIALS SUCH AS
RAGS AND SAWDUST WHICH HAVE ABSORBED CHROMIC ACID SOLUTION.
SUCH CONTAMINATED MATERIALS SHOULD BE IMMERSED IN A SOLUTION OF
SODIUM BISULPHITE TO NEUTRALISE THE CHROMIC ACID, THE SOLUTION
SHOULD THEN BE DISPENSED OF AS SPECIAL WASTE.

Page 8
Dec. 1/95
TSD
B. Nitric/Sulphuric/Phosphoric acid solutions
WARNING: 1. EVERY POSSIBLE CARE MUST BE TAKEN TO AVOID THE SOLUTIONS COMING
INTO CONTACT WITH THE EYES OR BARE SKIN, OPERATORS MUST WEAR THE
PROTECTIVE CLOTHING PROVIDED INCLUDING RUBBER GLOVES AND
GOGGLES.
2. EYE SPLASHES SHOULD BE TREATED IMMEDIATELY BY PROLONGED WATER

IRRIGATION OF THE EYES, FROM THE EYE-WASH BOTTLES PROVIDED, AND
REPORT FOR IMMEDIATE MEDICAL TREATMENT.

RUNNING WATER.
4. ALL BURNS, HOWEVER SLIGHT, SHOULD BE TREATED AT THE NEAREST

SURGERY OR FIRST-AID POST. THE SURGERY OR FIRST-AID POST MUST
BE TOLD WHICH SOLUTION (I.E. THE ACIDS INVOLVED) CAUSED THE
BURN.
SUBTASK 70-00-00-860-208-054
10.General
Electropolishing is a process which can be used to produce a surface suitable

for inspection or one with increased resistance to corrosion. It must be used
only when required by the Engine Manual, which will cover any specific
instructions necessary for a particular part.
SUBTASK 70-00-00-380-208-001
11.Processing - Electropolish Nimonic Turbine Blades

70-00-00-860-208-054 for general information
B. Descale and dress, if necessary, as instructed in the Engine Manual.
NOTE: It is important that metal should be free from scale or oxidation

before being subjected to electropolishing.
C. Vapour degrease the blades O.P.101 (TASK 70-00-00-100-101) and allow them
to cool.
NOTE: After degreasing, the blades should be handled wearing clean gloves.

Page 9
Dec. 1/95
TSD
D. Stop-off when required by the Engine Manual as follows:
(1) Stop-off the faces of the root platform and shroud adjacent to the
blade trailing edge by painting with OMat 7/40 stopping off lacquer,
red

(2) Allow the lacquer to dry for a minimum period of 10 minutes.
NOTE: Excess lacquer may be removed with OMat 7/102 thinners, high
flash cellulose.
E. Assemble the blades into the correct anode jig as described in the Engine
Manual. Ensure that the blades are correctly located and that the firtree
serrations of both blade and jig are clean to give a good electrical
contact.
F. If finger or other marks have inadvertently been made on the blade aerofoil
during stopping-off and jigging, wipe the affected area with a cotton-wool
pad moistened with neat OMat 1033A compressor oil
G. Inspect the assembled jig and ensure that:
(1) the area to be polished is clean and free from foreign matter; a slight
trace of soluble oil is permissible.
(2) The hooks are clean and free from burrs or any defect likely to prevent
good electrical contact with the anode busbar.
H. Immerse the assembly in the Nimonic electropolishing solution, detailed in

SUBTASK 70-00-00-180-208-001 and suspend it from the anode busbar by the
hooks; ensure that there is a good electrical contact with the bushbar.
I. Maintain the temperature of the solution at 28 to 35 deg.C. (82 to 95

deg.F.) during electropolishing and use a current density of 65 amp. per
square decimeter (sq.dm.) (4.2 amp. per sq.in.) for a period of 2 minutes
unless other instructions are given in the Engine Manual.
J. Swill the assembly, immediately on removal from the vat, in clean, cold
running water.
K. Remove the blades from the jig and again swill them in clean, cold, running
water.
CAUTION: BLADES IN NIMONICS OF LOWER NUMBERS THAN NIMONIC 95A MUST NOT BE
IMMERSED IN THE SOLUTION IN K.
L. Blades in Nimonic 95A or higher number will normally be covered with a dark
coloured smut. Immerse them in the hot nitric acid solution (Refer to
SUBTASK 70-00-00-180-208-002) for up to 5 minutes to dissolve the smut and
remove any copper deposit from the firtree roots.

Page 10
Dec. 1/95
TSD
M. Remove copper deposits from the firtree roots of blades in Nimonics of

lower numbers than 95A, by immersing these blades into the cold nitric acid
solution (Refer to SUBTASK 70-00-00-180-208-003) for sufficient time to
dissolve the copper.
N. Swill the blades in clean, cold, running water.

O. Immerse the blades in clean boiling water, for sufficient time for them to
achieve the temperature of the water.
P. Dry off the blades by means of a clean dry air blast.
SUBTASK 70-00-00-380-208-002
12.Processing - Electropolish Aluminium Compressor Blades


C. Mount the blades in the appropriate jig as described in the Engine Manual.
D. Vapour degrease the blades O.P.101 (TASK 70-00-00-100-101) and allow them
to cool.
E. Suspend the jig from the anode busbar so that the jig and blades are
immersed in the aluminium electropolishing solution detailed in SUBTASK
70-00-00-180-208-004
NOTE: Stainless steel cathode plates must be used.
F. Maintain the temperature of a solution at 60 to 70 deg.C. (140 to 158

sq.dm. (2.4 amp. per sq.in.) for a period of 1 minute unless other
instructions are given in the Engine Manual.
G. Remove the jig and blades from the solution and wash them thoroughly in two
separate clean warm water swills.
H. Immerse the jig and blades in clean, boiling water for sufficient time for
them to achieve the temperature of the water.
I. Dry off the blades using a clean dry air blast.

Page 11
Dec. 1/95
TSD
SUBTASK 70-00-00-380-208-003
13.Processing - Electropolish Aluminium/Bronze Compressor Blades
A. Refer to SUBTASK 70-00-00-860-208-053 for safety precautions SUBTASK



to cool.
CAUTION: COPPER CATHODE PLATES MUST BE USED IN OP. D.
immersed in the aluminium/bronze electropolishing solution detailed in
SUBTASK 70-00-00-180-208-005.
F. Maintain the temperature of the solution, at 50 to 60 deg.C. (122 to 140

sq.dm. (4 amp. per sq.in.) for a period of 1 minute unless other
G. Remove the jig and blades from the solution and wash them thoroughly in
clean, cold, running water.
H. Immerse the jig and blades in clean boiling water for sufficient time for
SUBTASK 70-00-00-380-208-004
14.Processing - Electropolish Steel Compressor Blades
A. Refer to SUBTASK 70-00-00-860-208-053 for safety precautions SUBTASK



Page 12
Dec. 1/95
TSD
to cool.
immersed in the steel electropolishing solution (Refer to SUBTASK
70-00-00-180-208-006).
NOTE: Stainless steel cathode plates must be used.
F. Maintain the temperature of the solution at 70 to 90 deg.C. (158 to 194

sq.dm. (6 amp. per sq.in.) for a period of 1 minute unless other
G. Remove the jig and blades from the solution and wash them thoroughly in two
separate clean warm water swills.
H. Immerse the jig and blades in clean boiling water for sufficient time for

Page 13
Dec. 1/95
TSD
Phosphoric acid content table

Fig.70-00-00-990-208-A01

Page 14
Dec. 1/95
TSD
Phosphoric acid content graph

Fig.70-00-00-990-208-B01

Page 15/16
Dec. 1/95
TSD
R FLUORESCENT PENETRANT INSPECTION

R TASK 70-00-00-200-210 Overhaul Process 210 - Fluorescent

R Penetrant Inspection
R SUBTASK 70-00-00-860-210-072
R 1. Contents
R General SUBTASK 70-00-00-860-210-054

R Safety Precautions SUBTASK 70-00-00-860-210-053
R Processing-General Application SUBTASK 70-00-00-230-210-001

R Surface Cleaning SUBTASK 70-00-00-110-210-073
R Oven Drying SUBTASK 70-00-00-230-210-077
R Cooling SUBTASK 70-00-00-230-210-074
R Application of Penetrant SUBTASK 70-00-00-230-210-075
R Remove surface penetrant SUBTASK 70-00-00-170-210-076
R Drying SUBTASK 70-00-00-230-210-003
R Developing SUBTASK 70-00-00-230-210-070
R Inspection SUBTASK 70-00-00-230-210-004
R Wipe off technique SUBTASK 70-00-00-230-210-078
R Protect the parts SUBTASK 70-00-00-620-210-001
R Local Application Procedures SUBTASK 70-00-00-230-210-002
R Control Checks and Process Maintainence SUBTASK 70-00-00-920-210-001

R Materials used in Process SUBTASK 70-00-00-860-210-051
R Materials Used in Control of SUBTASK 70-00-00-860-210-052
R Equipment and Materials
R Test Apparatus Suppliers SUBTASK 70-00-00-910-210-001
R Best Practice Guide SUBTASK 70-00-00-230-210-071
R SUBTASK 70-00-00-860-210-054
R 2. General
R A. This document establishes the minimum requirements for the liquid penetrant
R inspection of engine parts for the detection of surface breaking
R discontinuities in ferrous, non-ferrous and non-porous non-metallic
R materials.

Page 1
R May. 1/01
TSD
R B. Localised penetrant processing is only permitted on Group A major rotating

R parts in the following circumstances. Where the part concerned has
R previously been inspected, during the current shop visit, down a fully
R controlled processing line, including pre cleaning and oven drying to Table
R 1 and had all surfaces covered by penetrant. Reference should be made to
R Fig.70-00-00-990-210-002.

R C. Only post emulsifiable fluorescent penetrant is allowed on a group A, high
R energy rotating part unless specific dispensation is sought from
R Rolls-Royce plc.
R Such dispensation may be granted for components exhibiting complex

R geometric shapes, which prohibit controlled emulsification of the penetrant
R during penetrant removal.
R NOTE: A dispensation exists for the inspection of compressor drum

R assemblies, which shall be inspected using a high sensitivity
R fluorescent water washable penetrant (OMat 632).
R D. Penetrant systems controlled by this document shall be fluorescent

R penetrant, either Water Washable or Hydrophilic Post Emulsifiable. The
R penetrant system used shall consist of a family furnished completely by one
R manufacturer only. Materials of different families shall not be mixed,
R except that a developer from one manufacturer may be substituted for a
R developer from another manufacturer.
R E. Alternative penetrant techniques to those detailed in this specification

R shall only be used with the prior written approval of Rolls-Royce plc.
R F. Classification of penetrants - typical applications.
R (1) GROUP F1 - Fluorescent Penetrant - Water Washable - Dry Powder

R Developer
R Within this group there is a considerable variation from penetrant to

R penetrant in sensitivity and ease of removal from the surface of
R components. The group is divided into two broad classifications,
R standard sensitivity and high sensitivity. It shall be noted that
R penetrants within each sub-division do not have identical performance.
R (a) OMat 653 (MIL-I-25135/1A2)
R Standard sensitivity - readily removed from rough surfaces.
R For: Precision steel, light alloy casings NGV's, and sheet metal
R fabrications.
R (b) OMat 632 (MIL-I-25135/1A3)
R High sensitivity

Page 2
R May. 1/01
TSD
R For: Special applications only. Difficult to remove, required

R good, well cleaned, machined surface.
R (2) GROUP F2 - Fluorescent Penetrant - Post Emulsified - Hydrophilic

R Remover - Dry Powder Developer
R (a) OMat 650 (MIL-I-25135/1D2)
R Standard sensitivity
R For: Miscellaneous machined components.
R (b) OMat 651 (MIL-I-25135/1D3)
R High sensitivity
R For: Turbine blades, compressor blades rotating shafts demanding a

R higher level of sensitivity.
R (3) GROUP F3 - Fluorescent Penetrant - Post Emulsified - Hydrophilic

R Remover - Dry Powder Developer
R (a) OMat 652 (MIL-I-25135/1D4)
R Ultra-high sensitivity
R For: Critical rotating parts, e.g. local applications and special

R applications.
R G. General Requirements
R (1) Control
R The inspection process shall be instructed and controlled in accordance

R with the national controlling and regulating authority.
R (2) Personnel Qualification
R Personnel engaged in the execution of this specification shall be

R approved in accordance with the requirements of the national
R controlling regulatory authority, and meet the vision requirements of
R that authority.
R (3) Technique Instructions
R (a) The technique to be used for an inspection of any component shall

R be instructed on a Technique Instruction Card, controlled to the
R requirements of O.P.210 or the engine manual. The local Level 3 can
R authorise changes to the technique. The principle method, and
R process parameters within that method cannot be changed by a Level
R 3.

Page 3
R May. 1/01
TSD
R (b) Such documents shall be prepared and approved as defined by the

R local regulatory authority.
R (c) Where the Non Destructive Testing (NDT) instruction specified a

R penetrant classification only, e.g. O.P.210 standard sensitivity,
R then reference shall be made to an appropriate penetrant process

R chart containing detailed instruction. This shall be available to
R the penetrant operator. Such a chart shall be considered an
R extension to the NDT instruction and shall be formally controlled
R and kept up to date.
R H. Component Preparation
R (1) Parts to be penetrant tested shall be prepared by removal of

R contaminants which may hinder the entrance of penetrant to a defect.
R (a) Plasma spray coatings may cause varying levels of fluorescent

R background on the part. High background fluorescence reduces the
R contrast between detect indications and background (signal to noise
R ratio) with a corresponding decrease in inspection sensitivity.
R With certain types of coatings, it may be possible to perform an
R adequate inspection providing the coating is in good condition and
R the defect is open to the surface.
R (b) When penetrant inspection is carried out on coated surfaces there

R is a risk that the parent material may crack under the coating and
R not be detected.
R (c) Plasma Spray, flame spray, plating or paint should be removed prior
R to penetrant inspection if an inspection with a high level of
R sensitivity is required. Removal of these coatings must be
R specified in the inspection or repair documentation. If not
R specified, it will be assumed that inspections are to be conducted
R with the coating intact. Removal of these coatings should not be
R done in a manner which may cause metal smearing, or which leaves
R chemical residue on the part that may contaminate defects. See Fig.
R 70-00-00-990-210-001.
R (d) Peening operations should never be performed prior to penetrant

R application because the smearing and compressive stresses imparted
R by peening can completely eliminate the possibility of penetrant
R from entering a flaw.
R (e) Mechanical surface treatments such as abrasive blasting, sanding

R and burnishing operations can produce a smeared surface on some
R materials. If it is necessary to perform any of these operations
R prior to penetrant inspection, it is good practice to accomplish an
R acid etch prior to inspection.

Page 4
R May. 1/01
TSD
R (f) Etching shall only be carried out if specified by the inspection or

R repair documentation. Only approved etching procedures and
R consumable materials specified in the engine manuals for a specific
R part shall be permitted.
R SUBTASK 70-00-00-860-210-053
R 3. Safety Precautions
R WARNING: YOU MUST OBTAIN AND OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA
R FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE
R SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS,
R HUMAN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
R SUBTASK 70-00-00-230-210-001
R 4. Processing - General Application
R Refer to SUBTASK 70-00-00-860-210-053 for Safety Precautions, SUBTASK

R 70-00-00-860-210-054, for General and SUBTASK 70-00-00-860-210-051 for List of
R materials used in this process.
R For process flow charts see Fig. 70-00-00-990-210-003 Water washable

R fluorescent penetrant or Fig. 70-00-00-990-210-004 Post emulsified fluorescent
R penetrant.
R SUBTASK 70-00-00-110-210-073
R 5. Surface Cleaning
R A. Clean the part as described in the relevant Engine Manual.
R B. All surfaces to be inspected shall be clean, dry and free of soils, oil,
R grease, corrosion products, scale, smeared metal, welding flux, chemical
R residues or any other material that could prevent penetrant from entering a
R discontinuity, affect process performance or produce unacceptable
R background. Cleaning methods selected for a particular component shall be
R consistent with the contaminants to be removed and shall not be detrimental
R to the component or its intended function.
R The following are approved methods to be used as the final step prior to
R application of penetrant.
R (1) Aluminium and magnesium parts, refer to either TASK 70-00-00-100-101

R (OP 101) SUBTASK 70-00-00-110-101-001 (Vapour degreasing) or TASK
R 70-00-00-100-102 SUBTASK 70-00-00-110-102-001 (Aqueous degreasing).
R CAUTION: THE HOT AQUEOUS DEGREASING PROCESS (OP118), IS DETRIMENTAL TO

R ALUMINIUM. DO NOT USE THIS PROCESS ON ALUMINIUM ALLOYS.
Page 5
R May. 1/01
TSD
R (2) All other materials, refer to any of the methods TASK 70-00-00-100-101
R (OP 101) SUBTASK 70-00-00-110-101-001 (Vapour degreasing) or, TASK
R 70-00-00-100-102 SUBTASK 70-00-00-110-102-001 (Aqueous degreasing) or
R TASK 70-00-00-100-118 (OP118) SUBTASK 70-00-00-110-118-001 (Hot Aqueous
R degreasing).

R C. When cleaning using aqueous methods (O.P.102), attention shall be paid to
R the specific notes relating to the use of these processes before penetrant
R processing.
R (1) Washing shall be carried out IMMEDIATELY after the cleaning operation
R to prevent residual film on the surface or in a discontinuity.
R (2) The water used in washing shall be free of any contamination that will
R leave a residue on the component when dried. The use of corrosion
R inhibitors in the wash water is not permitted.
R (3) Before oven drying, surface water and entrapped water shall be removed
R by use of a syphon and air blast to aid drying and avoid staining.
R Manipulation of the part may be necessary to aid this process.
R SUBTASK 70-00-00-230-210-077
R 6. Oven drying after aqueous cleaning
R All parts shall be oven dried after aqueous cleaning.
R A. The temperature, pressure and drying time for oven drying shall conform to
R the requirements of Table 1. The default drying time and temperature is 60
R minutes at a minimum of 120 deg.C. (248 deg.F.), (with due regard that a
R selected temperature will not have an adverse effect on the parts).
R B. The drying time may only be reduced from 60 minutes in accordance with
R Table 1 provided that the minimum surface temperature is achieved. This
R must be demonstrated for specific parts using fixed loading plan and
R calibrated instrumentation.The results of this work shall be formally
R recorded and approved by the supervisor responsible.
R C. The oven used for drying shall be capable of raising parts to the required
R minimum temperature and maintaining the temperature for the specified
R drying time. An oven may be augmented with a pressure reduction capability
R (vacuum). Such an oven shall be purpose build and be fitted with a
R calibrated vacuum gauge and alarm to ensure correct pressure is maintained
R in the oven chamber throughout the drying cycle. The drying parameters
R shall be displayed on the oven.

Page 6
R May. 1/01
TSD
R D. Table 1 - Oven Drying
R Maximum
R Minimum surface pressure Reduced drying
R temperature during during the Default Dry time where
R the Oven Dry Cycle Drying Cycle Time permitted
R deg.C (deg.F) m bar Minutes Minutes
R 120 (248) 1000 60 10

R atmospheric
R 80 (176) 25 60 10
R 60 (140) 15 60 10
R 40 (104) 10 60 10
R less than not permitted not permitted not permitted

R 40 (104)
R E. On economic grounds, for large engine casings where existing ovens are not
R suitable, a temporary alleviation to use an alternative forced drying
R method is acceptable provided the method is specified on a local procedure
R and approved by a level 3.
R SUBTASK 70-00-00-230-210-074
R 7. Cooling
R Following any pre-treatment or surface penetration that heats the component,

R adequate cooling shall be allowed before penetrant is applied to the part. The
R surface of the part shall be cooled to a temperature of approximately 40
R deg.C. (104 deg.F.), which is roughly when the component may be comfortable to
R the touch.
R SUBTASK 70-00-00-230-210-075
R 8. Application of Penetrant
R A. The following penetrants are used in this process
R OMat 653 Fluorescent penetrant. Medium sensitivity water washable

R (MIL-I-25135/1A2)
R OMat 632 Fluorescent penetrant. High sensitivity water washable
R (MIL-I-25135/1A3)
R OMat 650 Fluorescent penetrant. Medium sensitivity, post-emulsified
R (MIL-I-25135/1D2)
R OMat 651 Fluorescent penetrant. High sensitivity, post-emulsified
R (MIL-I-25135/1D3)

Page 7
May. 1/01
TSD
OMat 652 Fluorescent penetrant. Ultra high sensitivity,

post-emulsified
(MIL-I-25135/1D4)
Penetrant shall be applied by spray, flow-on, brush or immersion technique

to provide the coverage as required. Where manual spray systems are used,

then a source of UV-A shall be provided in order to check that the
surface(s) to be tested is/are fully covered. Where penetrant seepage
creates problems for inspection, e.g. film-cooled turbine blades;
electrostatic application reduces the seepage.
(1) Ten to sixty minutes penetrant contact time shall be provided. Drain
time is considered to be part of the contact time and shall be treated
as such by draining for at least the minimum stipulated. In exceptional
circumstances, the minimum contact time may need to be increased, in
which case it will be referenced in the technique instruction.
(2) If the maximum drain time of 1 hour has been exceeded or any drying has
occurred, the penetrant shall be re-applied and a further contact time
of five minutes allowed.
(3) If drain time exceeds 2 hours the penetrant shall be re-applied and the
dwell time repeated. The total penetrant contact time permitted between
penetrant application and continuing the process is 4 hours. If this
time is exceeded, the part shall be re-cleaned and reprocessed.
(4) Draining can be carried out by suspension of a part over the immersion
tank. If penetrant is drained into a separate drop tray, it shall not
be re-used unless it is re-checked in accordance with SUBTASK
70-00-00-920-210-001 and found to be acceptable.
SUBTASK 70-00-00-170-210-076
9. Remove surface penetrant
A. Pre-Water Wash - Post Emulsified Penetrant
(1) The component surface shall be washed only to the point where the bulk
of the surface penetrant has been removed so as to minimise the degree
of penetrant contamination in the emulsifier bath. The time taken to
achieve this will vary depending on the component size and complexity.
(2) Water temperature shall be ambient between 10 deg.C. and 35 deg.C. (50
deg.F. to 95 deg.F.).
(3) Washing may be carried out by any or a combination of the following

methods:
(a) Air/water spray.
(b) Water spray

Page 8
R Oct. 1/02
TSD
R (4) For manual operation, the air/water or water spray gun shall be
R adjusted to give a spray of low velocity. The spray gun nozzle shall be
R held at least 300 mm (11.81in.) away from the component, paying
R particular attention to areas of entrapment such as undercuts, blind
R holes and oil ways.
R (5) Inlet air pressure shall not exceed 0.17 MPa (25 p.s.i.)
R (6) Inlet water pressure shall not exceed 0.17MPa (25 p.s.i.)
R (7) The water used in washing shall be free of any contaminant that will
R leave a residue on the component when dried.
R B. Hydrophilic Emulsifier - Post Emulsified Penetrant
R (1) Remover solution shall be applied to all areas of the component treated
R with penetrant. The application shall be by total immersion or as foam.
R Foam shall not contain emulsifier liquid flow or spray when applied.
R Any other form of remover application is not permitted.
R (2) Contact with remover shall be kept to a minimum consistent with

R acceptable background and must not exceed the maximum stipulated time.
R OMat 651, 2 minutes maximum, OMat 652, 4 minutes maximum. The quoted
R times include the travel time from remover to wash.
R (3) Agitation shall not be applied during the emulsification cycle.
R (4) The remover solution shall not exceed 20 % hydrophilic concentrate in

R water.
R (5) The type and concentration of emulsifier shall be clearly displayed on

R the tank.
R (6) The remover shall be at ambient temperature.
R (7) To arrest the action of the emulsifier, an agitated water wash may be
R used. Where required, this operation shall be carried out prior to, and
R in addition to, final spray wash.
R C. Water Wash for Water Washable Penetrant/Final Wash for Post Emulsified
R Penetrant
R (1) The component surface shall be washed only to the point where there is
R minimal background fluorescence. The time taken to achieve this shall
R be kept to a minimum and will vary depending on the component size,
R complexity and surface finish. Care must be exercised to ensure over
R washing does not occur.
R (2) In a manual line this operation shall be carried out in a suitably

R darkened are under ultra violet (UV) light such that the excess
R penetrant readily fluoresces.
Page 9
R May. 1/01
TSD
R (3) Water temperature shall be ambient between 10 deg.C. and 35 deg.C. (50
R to 95 deg.F.).
R (4) Washing may be carried out by any or a combination of the following

R methods.

R (a) Air/water spray.
R (b) Water spray
R NOTE: An agitated water wash bath may also be used in addition to

R the spray at the discretion of the level 3. This shall have
R a weir system to remove surface contamination.
R (5) For manual operation, the air water or water spray gun shall be
R adjusted to give a spray of low velocity. The spray gun nozzle shall be
R held at least 300 mm (11.81in.) away from the component, paying
R particular attention to areas of entrapment such as undercuts, blind
R holes and oil ways.
R (6) Inlet air pressure shall not exceed 0.17 MPa (25 p.s.i.)
R (7) Inlet water pressure shall not exceed 0.17 MPa (25 p.s.i.)
R (8) The water used in washing shall be free of any contaminant that will
R leave a residue on the component when dried.
R D. Hot Dip
R (1) Optional procedure intended to assist drying operation at the

R discretion of the level 3.
R (2) Perform the operation by dip into hot water, temperature 85 plus or
R minus 10 deg.C. (185 plus or minus 18 deg.F.) for 20 seconds maximum
R (3) A weir system is preferred to prevent contamination.
R SUBTASK 70-00-00-230-210-003
R 10.Drying
R A. Initial Air Dry
R (1) Excess water shall be removed using a clean, dry air and/or suction
R etc.
R (2) Air blast pressure shall not exceed 0.17 MPa (25 p.s.i.) at a distance
R not less than 300 mm (11.81in.) from the part to nozzle tip.

Page 10
R May. 1/01
TSD
R B. Final Oven Dry
R (1) The components shall be placed in a hot air circulating oven

R thermostatically controlled to a temperature of 70 plus or minus 10
R deg.C. (158 plus or minus 18 deg.F.).
R CAUTION: IN NO CIRCUMSTANCES CAN THE OVEN TIME EXCEED 20 MINUTES.
R (2) Drying time will vary with geometry mass and initial temperature of
R component, but it shall always be kept to a minimum.
R Parts left in excess of times quoted must be reprocessed.
R SUBTASK 70-00-00-230-210-070
R 11.Developing
R A. Dry Powder
R (1) The OMat 606 developer shall be applied as soon as possible after
R drying.
R (2) Powder shall come into contact with all surfaces of the component
R requiring inspection before removing excess powder by application of
R low pressure air blow off. Contact time shall be between 10 minutes and
R 3 hours.
R (3) Excess powder shall be removed by clean dry air blow off at a maximum
R air pressor of 0.068 MPa (10 p.s.i.) at a distance not less than 300
R mm. (11.81in.).
R (4) For routine inspection, methods of dry powder application are as

R follows:
R (a) Powder storm cabinet
R (b) Electrostatic spray
R (c) Powder spray gun

Page 11
R May. 1/01
TSD
R B. Non-aqueous Based Aerosol Spray Developer
R (1) Aerosol application OMat 617 may only be used when specified by the NDT
R instruction documents and in the following circumstances.
R (a) For in-situ and localised inspection, SUBTASK 70-00-00-230-210-002.

R NOTE: The term 'localised' can be defined as a specified local
R area of the whole component or a component feature requiring
R inspection. Localised inspection is not permitted on Class A
R major rotating parts, such parts must be completely cleaned,
R be oven dried and have all surfaces covered by penetrant as
R part of a controlled process:
R 1. When using the wipe off technique. Refer to SUBTASK

R 70-00-00-230-210-078.
R 2. After standard processing and inspection to enhance

R sensitivity in certain critical areas.
R NOTE: Be careful when applying non-aqueous based developers. An

R adequate coating has a white appearance, but the metallic
R surface background is visible. If the coating is too heavy,
R components shall be re-cleaned, dried and reprocessed.
R (2) When using non-aqueous based developers, inspection shall take place
R immediately after application followed by a further inspection after 20
R minutes. This avoids any confusion due to excessive bleed out and
R diffusion of indications.
R SUBTASK 70-00-00-230-210-078
R 12.Wipe off technique
R Wipe off techniques, when used as an aid to the interpretation of penetrant

R indications on components, shall be used with extreme caution. This technique
R shall only be applied once on any individual indication or area.
R A. Wipe across the indication once with a small cotton swab dampened with OMat
R 616 solvent penetrant remover. Do not permit solvent to flow or run over
R the surface.
R B. Allow surface to dry (solvent should evaporate rapidly).
R C. Allow a minimum of 1 minute to elapse after complete evaporation. View for

R reappearance of indication.
R D. Apply a light film of OMat 617 non-aqueous, solvent based developer by

R aerosol spray.
R Inspect immediately for repeat indications.

Page 12
R May. 1/01
TSD
R E. Allow 10 minutes to develop and re-inspect.
R F. Assess repeat indications against the relevant Quality Standard.
R G. If there is no repeat indication, examine under white light using viewing

R aid(s) at suitable magnification for cause of original indication. If the
R cause cannot be resolved, then locally re-process the area using the same
R penetrant as used in the initial inspection.
R H. With linear indications or a linear chain of dots, under no circumstances

R must it be assumed that if there is not a repeat indication (bleedback)
R that the original indication was not relevant.
R I. The cause of any indication shall be evaluated in white light using

R magnification where required, against the requirements of the relevant
R Quality Standard.
R J. Parts shall be cleaned and re-processed if background is excessive or any

R processing requirement has not been met.
R SUBTASK 70-00-00-230-210-004
R 13.Inspection
R A. Inspection under UV light shall take place after minimum contact time but
R within 3 hours of dry powder developer application. Visual aids may be
R required (e.g. mirrors, UV light guides etc.) on surfaces difficult to see
R by direct vision.
R B. The UV illumination at the surface to be inspected shall not be less than

R 1000 micro Watts/sq.cm. in a darkened area. Inspection shall be performed
R in an area protected from extraneous white light.
R NOTE: White clothing etc. can fluoresce and be a cause of extraneous white
R light. Where computer screens are used in the viewing area, a means
R of rapidly dimming the light output, such as a flip down screen,
R should be used.
R C. Ambient white light levels shall not exceed a maximum of 5 lux at the
R inspection surface.
R D. Inspectors, whilst carrying out penetrant inspection, shall not wear

R sunglasses or light sensitive lenses which darken when exposed to sunlight
R or UV light.
R E. A minimum of 3 minutes shall be allowed for eye adaptation to the darkened

R inspection conditions prior to inspection of parts. It may be necessary to
R extend this time when exposed to large changes in light levels.

Page 13
R May. 1/01
TSD
R F. As a guide to aid the sizing of fluorescent indications, plastic

R fluorescent comparators or special feeler gauges may be used. If these are
R used to finally sentence a part, they shall be calibrated.
R G. To aid the evaluation of an indication, the 'wipe off' technique may be

R used as described in SUBTASK 70-00-00-230-210-070.

R SUBTASK 70-00-00-620-210-001
R 14.Protect the parts
R A. Following inspection, parts shall be subjected to an air blow to remove

R developer powder. Where the presence of developer powder or other
R examination material residues is detrimental to subsequent operations or
R the parts intended function, specific cleaning requirements shall be
R specified.
R B. Protect from corrosion where necessary, using the temporary protectives

R described in TASK 70-00-00-300-340 (O.P.340).
R SUBTASK 70-00-00-230-210-002
R 15.Local Application Penetrant Procedure
R A. Refer to SUBTASK 70-00-00-860-210-053 for Safety Precautions, SUBTASK

R 70-00-00-860-210-054 for General and SUBTASK 70-00-00-860-210-051 for the
R list of materials used in this process.
R (1) Localised penetrant processing is only permitted on group A major

R rotating parts in the following circumstances. Where the part concerned
R has previously been inspected, during the current shop visit, down a
R fully controlled processing line, including pre cleaning and oven
R drying to Table 1 and had all surfaces covered by penetrant. Reference
R should be made to Fig.70-00-00-990-210-002. Only post emulsified
R fluorescent penetrant is allowed on a class A, high energy rotating
R part unless specific dispensation is sought from Rolls-Royce plc,
R SUBTASK 70-00-00-860-210-054

Page 14
R May. 1/01
TSD
R B. The application of penetrant to a specified local area of other components

R shall be a controlled process and is permissible, for in-situ applications
R such as on an installed engine. These may be processed to a local
R fluorescent penetrant process procedure defined in a technique instruction
R card as per ,Refer to SUBTASK 70-00-00-860-210-054. Individuals formulating
R or amending such process procedure instruction cards shall hold a current
R penetrant approval. Instruction cards shall be approved by a Level 3 in the

R penetrant method.
R (1) The technique instruction card shall address and describe the
R following, in addition to basic technique parameters:
R (a) Correct surface preparation and cleaning sequence immediately prior

R to penetrant application.
R (b) The capability and limitation of the technique e.g. restricted

R access for processing, restricted viewing due to adverse access and
R geometry, component condition, defect characteristics, reduced
R sensitivity and economic considerations.
R (c) A numbering system that uniquely identifies the technique.
R (d) Each instruction card shall identify a component part number,

R although where similarly designed components have a variety of part
R numbers, it is permissible to cover the NDT requirements on one
R instruction card using 'family' identification as against
R individual part numbers.
R 'Family' cards are only permissible where there is a formal system

R of traceability from individual part numbers to that family.
R (2) The issuing authority shall retain a master technique instruction card
R at each issue. Copies of the current issue master shall be available in
R each inspection area (previous issues to be destroyed).
R (3) Changes to an NDT technique instruction card may only be made by

R re-issue in its entirety.
R C. Following Local Inspection protect the parts refer to SUBTASK

R 70-00-00-620-210-001
R SUBTASK 70-00-00-920-210-001
R 16.Control Checks and Process Maintenance
R Refer to SUBTASK 70-00-00-910-210-001 for details of the suppliers of the

R Special Test Apparatus and to SUBTASK 70-00-00-860-210-052 for list of
R materials used in this process.

Page 15
R May. 1/01
TSD
R A. Control
R (1) Control checks and maintenance shall be carried out at the frequency
R specified in Tables 2 and 3 and the results recorded. Records shall be
R retained for one year, with the exception of annual calibrations, which
R shall be kept for a period of 3 years

R (2) Non-compliance with the parameters specified for the control checks
R shall be reported immediately to local supervision and rectified before
R commencing inspection.
R (3) It is the responsibility of the operators to ensure that they do not

R use penetrant equipment that is out of calibration without bringing
R this calibration status to the attention of their supervision.
R (4) The manager responsible for quality control shall be informed whenever
R it is suspected that components may have been accepted using
R uncontrolled processes or equipment.
R (5) Control of associated processes shall be to the relevant specification.
R (6) When changes have taken place, e.g., replacement Ultra Violet (UV)
R lamp, top up of tank etc., related control checks shall be carried out
R following such replacement/additions of these items.
R (7) Penetrant consumables are monitored for significant deterioration by

R control checks and maintenance. On this basis Shelf Life is not
R applicable.
R (8) Certain control checks require a comparison of penetrant to an unused

R standard. This standard shall be:
R (a) Of the same manufacture and type of penetrant.
R (b) Taken directly from a newly opened original container, but of a

R different batch.
R (c) Kept in darkened conditions in a sealed clearly labelled container.
R (d) No older than the manufacturers recommended shelf life or 2 years

R from the date of manufacture, whichever is the lesser.
R (e) Kept for exclusive use of comparison tests.
R (9) Ovens used to dry parts after aqueous processes such as cleaning and
R washing shall be controlled.
R
Page 16
May. 1/01
TSD
R Table 2 - Equipment Calibration Requirements/Frequencies
R INITIAL
R REQUIREMENT CALIBRATION SIX MONTHLY ANNUAL REQUIREMENTS
R Ultra-Violet * BS4489 plus or

R Monitor minus 5% or other

R equivalent National
R Standard
R White Light * BS667 or other

R Monitor equivalent National
R Standard
R Timers * Tolerance plus or

R minus 10%
R Pressure Gauges * Tolerance plus or

R - Air minus 10% of
R - Water specified pressures
R Temperature * Tolerance plus or

R Indicators minus 10%
R Refractometer * Initial calibration

R only. Check before
R use.
R Plant * Initial calibration

R Performance only.
R Test Panel
R Table 3 - Plant Performance Test - Frequencies
R CHECK SHIFT WEEKLY MONTHLY QUARTERLY ANNUALLY
R Plant performance *
R Gauges *
R Ultra-Violet Lamps *
R Air Line *
R Cleanliness
R Equipment *
R Fluorescent *
R Brightness
R Developer *

Page 17
May. 1/01
TSD
R CHECK SHIFT WEEKLY MONTHLY QUARTERLY ANNUALLY
R Remover *
R Ultra-Violet Lamp *
R Efficiency

R Fluorescent *
R Intensity
R Clean Tanks *
R Ambient White Light *

R Level
R Water Content *
R (water washable)
R Penetrants
R Automated Line *
R Conformance
R B. Shift Checks
R (1) Plant Performance
R (a) Plant performance shall be checked and recorded at the commencement

R of each shift using a Sherwin PSM5 or Magnaflux Z5 P/N 198055
R panel.
R (b) The panel shall have been initially calibrated.
R (c) A separate panel shall be available for each penetrant system in

R use.
R (d) The panel shall be subjected to a complete process cycle, after

R ensuring it is totally dry, and checking under UV light to confirm
R no trace of fluorescence.
R (e) The resulting indications shall be compared against the replica or

R photograph made for that particular panel/process at the initial
R calibration.
R (f) If the indications on the panel are not comparable to that of the
R replica or photograph, then the penetrant process shall not be used
R to inspect components until the fault is located and rectified. All
R components processed from the time of the last satisfactory plant
R performance check shall be considered to be inadequately processed.
R Suitable action must be taken to re-inspect. If not available for
R retest, Supervision and Quality Assurance shall be notified.

Page 18
May. 1/01
TSD
R (g) After use, the panel shall be cleaned by air blast followed by
R cleaning, refer to SUBTASK 70-00-00-100-210-073. It shall then be
R inspected under UV light and if any trace of fluorescence remains
R then surface cleaning shall be repeated. The use of air/water spray
R may be necessary prior to cleaning.
R (h) Store the test piece fully immersed in a sealed container of

R degreasing fluid, refer to TASK 70-00-00-100-101 (OP101) SUBTASK
R 70-00-00-100-101-003.
R NOTE: This is an overall check of plant and equipment. It is

R essential therefore, that the processed panel is checked
R under ALL UV lamps to be used for inspection during that
R shift.
R (2) Initial Calibration of Sherwin PSM5 or Magnaflux Z5 P/N 198055 Panel
R (a) This calibration is to be carried out initially. It need not be

R repeated unless equipment/process changes are made, damage occurs
R or the replica/photograph deteriorates.
R (b) Allocate the panel a unique identification relating it to a

R particular penetrant line and process.
R (c) Ensure the panel is thoroughly clean. This can normally be achieved
R by use of vapour phase degreasing followed by cooling to 40 deg.C.
R (104 deg.F.) or less, or by approved aqueous degrease. Refer to
R TASK 70-00-00-100-102 (O.P.102) SUBTASK 70-00-00-110-102-001.
R (d) Process the panel to the requirements of the appropriate process

R referred on the equipment for which the panel is to be the control,
R using unused penetrant materials.
R (e) Using either suitable replicating material obtainable from the

R penetrant supplier or a photograph, produce a replica of the
R cracked chromed areas. It is preferable that this replica is stored
R under subdued light conditions when not in use.
R (f) Suitably mark and identify the replica.
R (g) The following minimum number of indications shall be obtained:
R NEW
R MANUFACTURE MIL STANDARD NUMBER OF
R EQUIVALENT OMat NUMBER EQUIVALENT INDICATIONS
R F1B OMat 653 MIL-I-25135/1A2 3

R F1C OMat 632 MIL-I-25135/1A3 3
R F2A OMat 650 MIL-I-25135/1D2 4
R F2B OMat 651 MIL-I-25135/1D3 4
R F3 OMat 652 MIL-I-25135/1D4 5

Page 19
May. 1/01
TSD
R (3) Gauge Checks
R Verify that all gauges are in control, operative and that the correct
R working range as stated on the appropriate process chart is in
R operation.

R (4) Ultra-Violet Lamps
R Verify lamp serviceability.
R (5) Air Line Cleanliness - (Air Dry and Developer Removal)
R Air line cleanliness shall be checked by directing the air stream onto
R a sheet of white filter paper for 10 to 20 seconds at a distance of
R approximately 75 mm (3.0in.). If any fouling of the paper is evident,
R the line shall not be used until the cause is ascertained and
R corrected. All moisture traps must be checked, and if found full,
R emptied before the line is used.
R (6) Equipment
R (a) Check tank levels to ensure adequate volumes.
R (b) Check equipment is operative, clean and fit for use. Include
R inspection area and ensure freedom from fluorescent contamination,
R which may affect parts or degrade the inspection.
R C. Weekly Checks
R (1) Penetrant - Fluorescent Brightness Checks
R (a) A comparison of fluorescent brightness shall be made against a

R standard of unused penetrant. Thick check shall be carried out on
R penetrant material irrespective of application method.
R (b) An OMat 1/144 filter paper shall be soaked with the penetrant under
R test and another in an unused sample.
R (c) Dry both samples in an air circulating oven for five minutes at a
R temperature not exceeding 80 deg.C. and compare under a UV source.
R (d) If there is a visual difference in fluorescent brightness between

R the two samples, further tests shall be carried out. Refer to
R Quarterly Checks.
R (2) Developer Checks
R (a) Where OMat 606 developer powder is recycled and re-used, it shall
R be inspected to ensure it is dry and has not agglomerated.

Page 20
May. 1/01
TSD
R (b) It shall also be inspected under UV light source to ensure there is

R no fluorescent contamination. As a guide, no more than 10
R fluorescent specks observed in approximately a 10 cm (4.0in.)
R diameter circle of thinly spread developer.
R (c) Where fresh developer is used for each application such as

R electrostatic spray to waste, no weekly check is required but the

R developer shall be checked each time the bulk container is filled.
R (3) Remover Check
R (a) Remover concentration shall be checked using a Refractometer.
R (b) Variations of greater than plus or minus 3 percentage points (of

R the declared working concentration, which shall be stated on the
R tank side), are unacceptable.
R (c) Refractometers shall be initially calibrated by making a chart or

R graph relating refractometer readings to known remover
R concentrations in the range of usage and shall apply to all
R removers in use.
R (d) The calibration curve is produced by preparing five samples of

R remover, at 90%, 95%, 100%, 105% and 110% of the proposed working
R concentration. The refractive index of these samples are measured
R and plotted onto a chart to produce a calibration curve of
R refractive index verses remover concentration. A new calibration
R curve must be made whenever the make or type of remover is changed.
R Prior to use, the refractometer shall be zeroed in accordance with
R manufacturers instructions.
R D. Monthly Checks
R (1) Ultra-Voilet Lamp Efficiency and Maintenance
R WARNING: NEVER USE LAMPS WITH BROKEN FILTERS.
R (a) Inspect lamps for cracked and broken filters and any escape of
R unfiltered light.
R (b) Remove accumulation of dust or dirt on glass lamps and reflectors

R when cold.
R (c) The output of UV lamps used for inspection shall be measured using
R a radiometer, which responds to radiation in the UV-A range and
R conforms to the requirements of BS4489 or other equivalent National
R Standard.
R (d) The minimum intensity for UV-A radiation at the surface of the
R component necessary for satisfactory inspection is 1000 micro
R Watts/sq.cm.

Page 21
May. 1/01
TSD
R (2) Test Conditions
R (a) The lamps shall be switched on and allowed to warm up for a minimum
R of 20 minutes.
R (b) For fixed lamps, the intensity of illumination shall be measured at

R the inspection surface and shall be 1000 micro Watts/sq.cm.
R minimum.
R (c) For UV systems employing flexible light guides, or battery operated

R systems, the intensity of illumination shall be measured at a
R distance of 50 mm. (1.96in.) from the light guide lens and shall be
R a minimum of 1000 micro Watts/sq.cm. Maximum working distance to be
R marked on the lamp.
R (d) For all other lamps used for inspection, the intensity of
R illumination shall be measured at a distance of 380 mm. (14.96in.)
R from lamp/filter to monitor.
R (e) Move the UV monitor in a plane at right angles to the beam of the
R lamp until a maximum reading is obtained.
R (f) Reject the lamp if the readings are less then 1000 micro
R Watts/sq.cm.
R NOTE: For the purpose of calibration for UV-A radiation intensity,

R the lamp, lamp holder and transformer shall be considered to
R be a single unit. Lamps shall not be changed to a different
R lamp holder without repeating the test.
R (3) Ambient white light levels shall be measured at the working surface. A
R maximum level of 5 lux at the inspection surface is allowed.
R (4) Water Contents (Water Washable Penetrants Only OMat 632, OMat 653)
R Water content of in-use water washable penetrants shall be measured in

R accordance with ISO9029 or other National Standard. (Not necessary
R where fresh penetrant is applied from an enclosed container via spray
R to waste).
R Water content in excess of 5% by volume is unsatisfactory.
R (5) Automated Process Lines
R Automatic process lines shall be checked to ensure the actual operation

R is consistent with that selected on the program and conforms to
R O.P.210.

Page 22
May. 1/01
TSD
R E. Quarterly Checks
R (1) Measurement of Fluorescent Intensity
R (a) Where the penetrant liquid is used, irrespective of application

R method, a comparison of fluorescent intensity shall be made against
R a standard of unused penetrant.
R (b) Using the following method, produce two 1% solutions of penetrant

R in OMat 150 acetone. One using standard unused penetrant, the other
R using penetrant from the process line under test.
R (c) Using two pieces of filter paper, e.g. Whatman 541 or (OMat 1/144),
R soak one in each of the prepared solutions and then dry them in an
R air circulating oven for five minutes at a temperature not
R exceeding 80 deg.C. (176 deg.F.).
R (d) The intensity of the visible light emitted from the test sample is
R compared to that from the standard sample when both are excited by
R UV light from a stabilised inspection lamp.
R (e) If the variation of emitted light intensity between the two samples
R is greater than 10%; the penetrant shall be rejected.
R (f) The comparison is carried out by one of the following methods. In

R both methods the UV light intensity shall be the same on each
R sample and a minimum of 1000 micro Watts/sq.cm.:
R (i) Using a Direct Reading White Light Meter:
R Position a white light meter directly under a stabilised UV

R lamp. Place one of the filter paper samples on the measuring
R lens of the meter such that it completely covers the light
R sensing area. After taking the reading, repeat the operation
R by substituting the other filter paper sample.
R (ii) Using a Levy West Type Ultra-Violet Monitor:
R Position the UV monitor directly under a stabilised UV lamp.

R Replace the phosphor screen in the monitor with one of the
R filter paper samples. After taking the reading, repeat the
R operation but substituting the other filter paper sample. For
R this, the filter paper samples shall be the same size as the
R phosphor screen, 80 mm x 80 mm (3.15 x 3.15in.)

Page 23
May. 1/01
TSD
F. Annual Checks
(1) Tank Cleaning
All tanks shall be cleaned as necessary and at least once a year to

prevent the onset of corrosive elements and restrict the build up of

impurities, which could contaminate components lowered into the tank
bottom.
The tank contents should be allowed to settle. Penetrant shall then be

drained to a level of 75 to 100 mm. above the tank base. This residue
shall be discarded and the tank thoroughly cleaned prior to refilling.
G. Penetrant Inspection Process Materials
The materials shall be approved by Rolls-Royce plc. See SUBTASK

70-00-00-860-210-051.
(1) The penetrant system used shall consist of a family furnished

completely by one manufacturer only. Materials of different families
shall not be mixed, except that a developer from one manufacturer may
be substituted for a developer from another manufacturer.
SUBTASK 70-00-00-910-210-001
17.Test Apparatus Suppliers
A. Combined ultra violet and white light meters
Levy Hill MkV and MkVI
Applied Scintillation Technologies Ltd

8 Roydonbury Industrial Estate
Harlow
CM19 5BZ
R Ardrox DLM1000 or BCI 95
Brent Chemicals
Aerospace Systems Group
Brent Europe Ltd
Ridgeway
Iver
Bucks
SL0 9JJ
Spectronics D.S.E. 100X

Page 24
R Jul. 5/04
TSD
R Burmah Castrol Ltd

R Burmah House
R Piper Way
R Swindon
R Wilts
R SN3 1DE
R B. Ultra violet light meter
R J221
R Ultraviolet Products Inc.

R San Gabrial
R California 91778
R USA
R C. White light meters
R Minolta T1
R Minolta
R Tanners Drive
R Bladelands North
R Milton Keynes
R MK14 5BU
R Megatron DL5, DL3 or DL3/C
R Megatron Ltd
R 165 Marlborough Road
R London
R N19 4NE
R SUBTASK 70-00-00-860-210-051
R 18.Materials Used in Process
R OMat 653 Fluorescent penetrant. Medium sensitivity water washable

R OMat 632 Fluorescent penetrant. High sensitivity water washable
R OMat 650 Fluorescent penetrant. Medium sensitivity, post-emulsified
R OMat 651 Fluorescent penetrant. High sensitivity, post-emulsified
R OMat 652 Fluorescent penetrant. Ultra high sensitivity,
R post-emulsified
R OMat 621 Fluorescent penetrant remover (hydrophilic)
R OMat 606 Fluorescent penetrant developer powder
R OMat 616 Solvent penetrant remover
R OMat 617 Non-aqueous aerosol developer
R OMat 2/101 Absorbent cloth, lint free

Page 25
May. 1/01
TSD
R SUBTASK 70-00-00-860-210-052
R 19.Materials Used in Control of Equipment and Materials
R OMat 150 Acetone

R OMat 1/144 Filter paper

R OMat 606 Fluorescent penetrant developer powder
R SUBTASK 70-00-00-170-210-A01
R 20.Remove surface penetrant
R A. Subtask deleted see SUBTASK 70-00-00-170-210-076
R SUBTASK 70-00-00-620-210-002
R 21.Protect Parts
R A. Subtask deleted see SUBTASK 70-00-00-620-210-001
R SUBTASK 70-00-00-230-210-071
R 22.Fluorescent Penetrant Inspection - Best Practice Guide
R The following table encapsulates a best practice guide to the process of

R fluorescent penetrant inspection.
R PROCESS GOOD PRACTICE WHY
R Quality, refer to SUBTASK 70-00-00-860-210-054 .
R Quality Personnel applying these Misunderstanding leads to

R processes should be capable mistakes
R of assimilating the written
R and verbal languages used
R Quality Managers, supervisors and Managers should gain an

R team leaders should gain a understanding of the process for
R formal appreciation of the which they are responsible
R key issues associated with
R the total penetrant process
R Process Control, refer to SUBTASK 70-00-00-920-210-001

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R Process When recording process log, Makes log recording less

R Control write measured values, not automatic, and therefore less
R just pass/fail or sign off prone to sign off error.
R Example: Record output of UV Allows capture of more useful
R inspection light as 17,500 process data.

R watt/sq.m., not just pass Example: deterioration of UV
R for exceeding process light can be seen by decreasing
R standard readings, so that a replacement
R can be ordered before light fails
R to meet standard
R Process Allow good access room If maintenance access is poor,

R Control around all equipment and maintenance may be postponed or
R booths for maintenance even forgotten, reducing process
R control effectiveness.
R Poor access increases the time
R required for maintenance,
R increasing process downtime
R Process Ensure that operator follows Contamination of gloves can

R Control good practices of washing or spread to components, masking
R discarding gloves at smaller cracks.
R different points in Penetrant on gloves will
R processing fluoresce in reading booth and
R cause glare to the inspector,
R reducing crack visibility
R Process Ensure the special needs of To assist in maintaining the

R Control individuals are met integrity of the operation
R Process Reduce light levels around Reduced light levels speed dark
R Control any areas where UV light is adaptation to improve indication
R used visibility under UV light.
R Reduced light levels minimise
R white light penetration of areas
R where tasks are carried out under
R UV light
R Process Ensure that the penetrant Holding time between tasks

R Control process is a contiguous introduces contaminants
R process consisting of
R cleaning, penetrant
R processing, viewing,
R interpreting and sentencing

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R Cleaning refer to SUBTASK 70-00-00-110-210-073
R Cleaning Maintain good communications Appreciating each others jobs

R Fig. between cleaning and FPI. helps all operators work in a

R 70-00-00 Example: Encourage meetings, more knowledge based manner. This
R -990-210 joint training, periods as can reduce errors and help to
R -001 helpers in each others cope with unusual conditions.
R department. If the return process is too
R Example: Good process for informal, it may encourage poor
R returning components to cleaning. If the return process
R cleaning is too punitive, an unofficial
R process may be invented. Both can
R increase overall errors
R Cleaning Ensure that system for Simple, visible system reduces

R matching components and probability of parts going
R paperwork is simple and through wrong cleaning process.
R visible Simple visible numbers aid
R process logging, e.g. for timing
R in and out of tanks or dryers
R Cleaning Have clearly visible and Process timing can be critical so

R audible timers on each that using a clock on a wall or a
R process, and train operators wristwatch can produce timing
R to use them errors that reduce cleaning
R effectiveness
R If times are easy to re-set,
R clearly visible and audible from
R all parts of the cleaning
R department, then operators can
R plan their work for efficiency
R while reducing errors
R Cleaning Ensure that the material If an operator moves a part in

R handling system between the wrong direction,
R tanks has controls which are metal-to-metal contact can occur,
R conveniently located and peening small cracks and making
R which move in the correct them more difficult to detect.
R sense. Movement errors can be prevented
R Example: Hoist controls move with controls located between
R up to raise, and in the waist and shoulder height, and
R correct directions to move which move in the correct sense
R along the line

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R Cleaning Have clearly specified and Clearly identified tools reduce

R marked cleaning tools for the probability of errors
R different components, and
R train operators which to
R use.
R Example: Marked hangers for
R tools in different parts of
R the cleaning area
R Cleaning Design process indicator Indicators are only useful if

R dials (e.g. temperature, they are easy to see and
R water pressure) to be easily interpret. Errors will go
R readable. Place them at eye unnoticed if dials are at knee
R height with appropriate height, or are difficult to
R lighting interpret and record
R Cleaning Train cleaners how to Improperly cleaned components

R recognise when a part is cause re-cleaning delays, or
R adequately cleaned. This is reading errors. Unless the
R best done by having FPI cleaners can recognise good
R inspectors involved in the cleaning (e.g. no dirt inside
R training grooves or holes) they cannot
R ensure that cleaning is adequate.
R FPI inspectors can show
R inspectors poor cleaning after
R penetrant application and help
R them recognise visible
R indications of poor cleaning
R Cleaning Load components so as to Metal to metal contact can peen

R avoid metal-to-metal contact cracks, making them more
R difficult to detect.
R Small cracks may be initiated
R Cleaning Design hangers/baskets to Transferring liquids between

R prevent liquid collecting in processes prevents thorough
R components when transferring liquid/component contact.
R between processes Transferring liquids between
R processes contaminates downstream
R processes
R Cleaning If separate lines for each Sending parts through the wrong
R cleaning process, label cleaning line is a rare error but
R lines as well as individual one which can reduce cleaning
R processes with clear, effectiveness, causing delays for
R understandable and visible re-cleaning.
R labels. If lines have understandable as
R Example: F2A in clear well as technical labels, errors
R contrasting letters are less likely and training is
R more rapid
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R Cleaning Label all process tanks and Errors in moving components to

R booths with clear, the wrong tank are rare, but can
R understandable and visible reduce cleaning effectiveness and

R labels. cause cross-contamination of
R Example: Penetrant as well tanks.
R as Ardrox 985-P13 If tanks have understandable as
R well as technical labels, errors
R are less likely and training is
R more rapid
R Cleaning Design handling system using Reduces contamination between

R materials which do not tanks and contamination of
R absorb chemicals components
R Cleaning Specify line to be used and Specification in understandable

R Fig. order of processes clearly terms increases redundancy of
R 70-00-00 on documentation, using both information, therefore reducing
R -990-210 understandable and technical errors.
R -004 terminology Clearly marking the documentation
R for each component, e.g. using
R different colours of cleaning
R paperwork for different lines,
R reduces wrong-line errors and
R reduces training times
R Loading, refer to SUBTASK 70-00-00-230-210-001
R Loading Provide custom hangers for Prevent metal-to-metal contact

R specific parts of the that can peen cracks over and/or
R process. Label them clearly initiate small cracks.
R and train loading personnel Allow easy rotation and movement
R in how to choose them. If throughout process, but
R there are many, you can even especially in the reading booth.
R specify which hanger on the Prevent wrong choices of hanger
R process traveller by training and labelling
R Loading Provide convenient means for Serial numbers can be difficult

R checking component serial to read without good lighting,
R number before component and and difficult to compare to
R paperwork are separated. paperwork if long strings of
R Example: Provide good numbers are involved. Mismatched
R lighting at the load serial numbers can waste
R component position and have processing time and inspection
R place to hold the paperwork effort until the mismatch is
R close to the component while discovered
R serial number is checked

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R Loading Provide well designed job The loading step is the most
R Fig. aid at loading to ensure all procedural in FPI, so can be
R 70-00-00 functions are completed. supported by simple job aids.
R -990-210 Example: Simple checklist These help ensure that steps are
R -004 for steps, or list of steps not omitted in this repetitive

R mounted on wall. function
R Loading Design handling system, If components hit each other the

R overhead hoists or roller metal-to-metal contact can peen
R conveyors, so that adjacent cracks and/or initiate small
R components cannot contact cracks.
R each other during processing As components tend to travel
R through the FPI process in
R batches, the handling system
R design should not rely on error
R free human performance to prevent
R metal-to-metal contact
R Loading Ensure that each component Good re-matching system ensures

R and accompanying paperwork correct identification of often
R can be re-matched easily similar components. This prevents
R errors that are only discovered
R later when serial numbers are
R re-matched
R Loading Design cranes, conveyors and The handling system and the
R other handling systems to component hanger must be designed
R avoid metal-to-metal contact together so that component does
R at all process stages. not contact metal, such as hooks
R or chains, throughout the FPI
R process. Metal-to-Metal contact
R can peen small cracks, and/or
R initiate small cracks.
R Loading Design cranes, conveyors and Ergonomic design prevents

R other handling system injuries and promotes safe use.
R components to ergonomics Poorly designed equipment
R standards. encourages operators to use
R Example: Roller conveyors unapproved shortcuts that can
R should be at about 1 m. reduce inspection effectiveness.
R (39.37in.) from ground for Controls should be operable
R safe listing. without reaching, bending or
R Example: Controls should be stretching, for safe use.
R located between waist and Controls should move in the
R shoulder height, 1 to 1.7 m. expected direction: up for on or
R (39.37 to 66.92in.) and raise; left for left movement,
R should move in the same etc.
R sense as the component

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R Loading Provide suitable equipment Ensures that processing time is

R and training to allow not waster on poorly cleaned
R operator to judge whether components. Discovery of poor
R cleaning is adequate. cleaning at the reading booth

R Example: Suitable lighting disrupts the schedule and wastes
R and clean swabs to check for inspectors time.
R dirt or oil in holes, Rejection before processing
R grooves, dovetails or prevents inspectors from trying
R firtrees to inspect a poorly cleaned
R component, which could lead to
R missed indications
R Loading Design handling system and If the hanger or conveyor

R hangers to prevent prevents liquids from reaching
R entrapment of air such that any part of the component, the
R penetrant, emulsifier, water subsequent inspection will not be
R and developer can reach all complete
R parts of the component
R Loading Design handling system and If liquids can be retained by the

R hangers so that component or hanger, subsequent
R contamination between processes will be contaminated.
R processes is minimised. This can reduce process purity,
R NOTE: This may mean that and/or make reading more
R component needs to be moved difficult and error prone
R on hanger or conveyor during
R processing
R Apply penetrant, refer to SUBTASK 70-00-00-230-210-075
R Apply Train operators to move Incomplete coverage can cause

R penetrant spray gun and component so cracks to be missed where no
R (spray) that all areas can be penetrant was applied
R reached
R Apply Make the spray gun easier to A more manageable spray gun helps
R penetrant manoeuvre by suspending or the operator reach all areas of
R (spray) balancing the weight of the the component, preventing missed
R hose. Also choose the cracks where no penetrant was
R lightest and most flexible applied.
R hose. Choosing a light and flexible
R hose, and balancing its weight
R makes the gun more manoeuvrable
R Apply Design process indicator Indicators are only useful if

R penetrant dials (e.g. temperature, they are easy to see and
R (spray) water pressure) to be easily interpret. Errors will go
R readable. Plate them at eye unnoticed if dials are at knee
R height with appropriate height, or are difficult to
R lighting interpret and record
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R Apply Label all process tanks and Errors in moving components to

R penetrant booths with clear the wrong tank are rare, but can
R (tank) understandable and visible reduce cleaning effectiveness and
R labels cause cross-contamination of

R Example: Penetrant as well tanks.
R as Ardrox 985-P13 If tanks have understandable as
R well as technical labels, errors
R are less likely and training is
R more rapid
R Apply Design the drum to spray gun Applying the wrong penetrant can
R penetrant connections so that each reduce crack visibility,
R (spray) spray gun can only be particularly for small cracks.
R connected to the correct Physically different fittings
R drum. reduce the probability of a wrong
R Example: Different sized connection to zero.
R fittings, reversal of male
R and female coupling on line
R Apply Make spray guns for Error of using the wrong spray
R penetrant water-soluble and post gun can reduce visibility of
R (spray) emulsifier penetrants cracks, particularly small
R clearly distinguishable. cracks.
R Example: Different designs The more ways in which the spray
R of gun, different colours of guns are different, the more ways
R gun, holders on different to prevent this error. Small
R sides of spray booths, large technical labels are not
R labels visible under UV sufficient to eliminate this
R light error.
R Apply Perform spraying under UV Fluorescence of penetrant makes

R penetrant light with a minimum of it easier to ensure complete
R (spray) white light, e.g. walk-in penetrant coverage of part. This
R booth with UV light only reduces the probability of
R missing a crack because it never
R received penetrant
R Apply Locate process gauges, e.g. Before each application process

R penetrant for line pressure or gauges should be checked to
R (spray) temperature, between waist ensure process is in control. The
R and shoulder height and easier the gauges are to check,
R design them to be easy to the more often this rule will be
R read under UV illumination followed

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R Apply Ensure that timer system for A single timer for penetrant
R penetrant penetrant application is application cannot be used for
R (spray) flexible enough to handle multiple components unless they
R real operations are carefully and visually

R Example: Separate timing for batched. Multiple timers or large
R each component or timing for display board for recording times
R clearly marked batch of are required if parts are not
R components batched.
R Apply Locate electrical controls Dark adaptation can be ruined by

R penetrant (e.g. for UV and white inadvertent use of white light.
R (spray) lights, timers) where they Good location and labelling of
R are clearly visible and controls helps prevent this error
R clearly labelled
R Apply Keep extraneous hoses and Any extraneous equipment can be

R penetrant spray guns (e.g. for used by mistake instead of the
R cleaning booth) out of spray correct equipment, potentially
R booth stopping the processing of a
R component.
R The less equipment that is in the
R spray booth the easier it is to
R provide visual control over the
R entrance of unapproved substances
R Water Wash, refer to SUBTASK 70-00-00-170-210-076 .
R Water wash Design wash booth so that Convenient positioning of the

R component can be washed component helps ensure that all
R between shoulder and elbow penetrant or emulsifier is
R height removed, improving visibility of
R cracks and reducing false
R indications
R Water wash Provide a clearly visible Emulsifier timing is critical and

R and audible timer for needs to be done in seconds, not
R emulsifier dwell time minutes. Excess time in the
R emulsifier can reduce crack
R detectability, particularly for
R small cracks.
R A larger visible timer, easily
R set in seconds, helps operators
R plan their spraying and waiting.
R A loud end signal ensures that
R operator interrupts other tasks
R to begin washing the component

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R Water wash Perform washing under UV Areas of the component retaining

R lighting, with minimal white penetrant are much easier to see
R light under UV lighting. This leads to
R more thorough washing, improving
R crack visibility
R Water wash Train operators to move wash Incomplete coverage can cause
R gun and component so that cracks to be missed where no
R all areas can be reached penetrant was applied.
R Water wash Make the wash gun easier to A more manageable wash gun helps
R manoeuvre by suspending or the operator reach all areas of
R balancing the weight of the the component, preventing missed
R hose. Also choose the cracks where penetrant was not
R lightest and most flexible removed.
R hose Choosing a light and flexible
R hose, and balancing its weight
R makes the gun move manoeuvreable
R Water wash Design displays for water If water and air pressure are
R and air pressure to be incorrect, too much penetrant may
R easily legible under UV be washed from cracks, making
R light. Locate them at eye them less easy to detect.
R height Convenient and legible displays
R help ensure that they are used
R for every component processed
R Water wash Provide air line and suction Water accumulation in pockets of
R hose to remove excess water, a component will not be dried in
R particularly where water can oven, leading to incomplete
R accumulate in a component. developer coverage, which reduces
R Ensure that air line and crack visibility.
R suction hose do not have Using plastic or rubber nozzles
R metal nozzles on air hose and suction hose
R reduces risk of metal-to-metal
R contact which can peen cracks,
R particularly small cracks or lead
R to in-service component failure.
R Water wash Train operators to provide Even with suitable tools and work
R complete coverage of all area, training is important to
R components in emulsifier ensure full coverage of each type
R application, wash and water of component, enhancing crack
R removal visibility.
R Operator knowledge of particular
R components helps them perform
R their tasks more thoroughly

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R Drying, refer to SUBTASK 70-00-00-230-210-003
R Drying Either provide a system for Timing of drying and developer

R timing each component in application must be well

R drying and developing, or controlled for maximum visibility
R use clearly marked batches of cracks.
R of components with a single One timer (or recording) per
R timer for each process. component is required if
R Example: Use a display board components flow individually. If
R to write in and out times of components are batched, a single
R individual components. timer can be used for the whole
R Example: Use coloured tags batch, but the batch must have a
R to visually indicate clear visual indication to avoid
R batches, and time each batch errors
R as a single item
R Drying Train operators to move If water pocket in component is

R components in dryer if water not completely dries, developer
R can accumulate in component will not have complete coverage,
R with potential for missing cracks
R Drying Controls and displays for Dryer temperature must be

R dryer temperatures should be controlled to ensure correct
R at eye height and be easy to processing for maximum crack
R set/read visibility.
R Well designed displays at eye
R height help ensure that dryer
R temperature is checked for each
R component processed
R Developing refer to SUBTASK 70-00-00-230-210-070
R Developing When developer is applied to Developer powder penetrates

R a component ensure even and holes, etc. well, but component
R gentle coverage of all areas must be completely immersed in
R developer cloud for full
R coverage. Incomplete coverage
R reduces crack visibility
R significantly
R Developing Make low pressure air hose Excess developer powder will
R available to blow off excess contaminate reading booth.
R developer powder Excess developer powder can
R distract from the search process
R in reading booth

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R Reading refer to SUBTASK 70-00-00-230-210-004
R Reading Keep reading booth separate Prevents accumulation of personal

R from inspectors 'home' area possessions in reading booth.
R This reduces distractions,

R prevents penetrant contamination,
R and gives visual control over
R entry of non-approved substances
R into reading booth
R Reading Provide timer in booth to Dark adaptation is essential to

R indicate dark adaptation defect visibility. Without dark
R time. Train inspectors that adaptation only large indications
R adaptation is needed after can be seen.
R EVERY white light exposure The dark adaptation process is
R and that the time for widely misunderstood. Many
R adaptation is commensurate inspectors believe that a time
R to the level of exposure. much shorter than the recommended
R NOTE: Other work can be done time applies to them. After about
R during this time provided 8 minutes in darkness, the eye is
R the inspector does not view about 100 times as sensitive as
R bright objects when first entering a darkened
R room.
R Inspectors are eager to get on
R with the reading, and often
R overestimate how much adaptation
R time has passed
R Reading Ensure that other objects in Any object fluorescing under UV

R the reading booth are not light becomes a glare source
R fluorescent. which decreases the visibility of
R Example: Inspectors defects, particularly small
R clothing, gloves inspection defects
R paperwork
R Reading If there is a computer Bright computer screens can

R terminal in the display provide a source of glare, and
R booth, provide a rapid means reduce dark adaptation. Both will
R of lowering its brightness reduce defect visibility,
R when the booth is darkened particularly for small defects.
R or better still, programs NOTE: The dimmer screen will be
R should be coded such that adequately visible when the eye
R text/images are displayed in is fully adapted
R shades of red.
R Example: Flip-down dark
R plastic screen, or
R two-position brightness
R switch

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R Reading Provide surface for Prevents physical damage to

R inspecting which is soft and components from contact with
R easy to clean. An example surface.
R would be black plastic Reduces change of component

R falling off inspection surface.
R Prevents penetrant contamination,
R which reduces defect visibility,
R particularly for small defects
R Reading Choose materials for hangers Prevents physical damage to

R that are yielding but will components from contact with
R not retain penetrant hanger which may lead to the
R initiation of small cracks.
R Prevents penetrant contamination
R that reduces defect visibility,
R particularly for small defects
R Reading Ensure that all tools, such Metal-to-metal contact can peen
R as UV light, white light, cracks, especially smaller
R magnifier, ruler, cannot cracks, making them less visible.
R make metal-to-metal contact Metal to Metal contact can
R with the component. scratch the component, giving a
R Plastic coverings are false indication in future
R recommended but they must be fluorescent penetrant inspections
R maintained or may lead to the initiation of
R small cracks.
R Reading Use filtered UV lamps at all UV light may be harmful

R times.
R Reading Use markers on component to Rotating components have no

R show where inspection visually obvious starting point,
R started and how inspection so that a start marker is needed
R is progressing. Makers to show when each circuit of
R include approved pens and visual search has been completed.
R taper for starting marker, If no marker is used, part of the
R and moveable sticker for component may not be inspected.
R progress marker. The As search progresses, any
R inspectors hand, which is interruption can cause inspectors
R steadying the component, can to lose their place in the
R be used as a moveable marker search, leading to parts of the
R if it does not contaminate component not being inspected
R the part, and if it is never
R needed for other activities

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R Reading Have low pressure air in the Dust specks can adhere to the
R reading booth to blow away component surface where they
R fluorescing dust specks become false indications, which
R slow and distract the search
R process.
R Gentle air blowing is preferable
R to either hand wiping or mouth
R blowing as it prevents surface
R contamination
R Reading Use a consistent and A good search strategy ensures

R systematic search strategy complete coverage, preventing
R in inspecting the component missed areas of inspection.
R A consistent strategy will be
R remembered better from component
R to component, reducing memory
R errors
R Reading Jig the inspection to ensure Collectively these improve the
R full systematic coverage of inspection capability and
R the part and provide reliability
R adequate illumination
R Reading Train inspectors in a A consistent search strategy

R consistent strategy of eye ensures complete converge of each
R movement for inspecting hole or dovetail/firtree. This
R holes and blade prevents missing areas of high
R dovetails/firtrees physical stress where small
R cracks are more likely
R Reading Ensure that inspectors allow Inspectors underestimate the time

R the correct time for an needed for bleeding back.
R indication to bleed back Inspectors overestimate the time
R after application of the which has elapsed since solvent
R wipe off technique applied.
R NOTE: Both reasons result in an
R indication not bleeding back
R sufficiently for detection during
R the inspectors viewing time
R Reading Eliminate white light leaks White light causes loss of dark
R into reading booth. adaptation, which reduces the
R NOTE: Even if the minimum visibility of defects,
R white light level is particularly small defects
R satisfied at the surface of
R the component, there may
R still be white light sources
R visible from the inspectors
R position

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R Reading When an indication is found Every time a white light is used

R under UV light, mark it in the booth, dark adaptation is
R temporarily and complete UV lost, which reduces the
R inspection before checking visibility of defects,

R the indication under white particularly small defects
R light
R Reading Provide both fixed area and A large diffuse UV source

R portable UV illumination in provides unchanging, even
R the reading booth illumination of the component,
R while a spot UV source provides
R brighter illumination that can be
R aimed as needed. This combination
R allows the inspector to obtain
R appropriate illumination at any
R point on the component
R Reading Provide easily adjustable Comfortable seating increases

R seating for the inspector inspection effectiveness. Easily
R which affords operating adjusted seating allows
R efficiency and comfort inspectors to keep their eyes at
R the correct location throughout
R inspection
R Reading If the inspection is Unless inspectors can put their

R performed on a table, allow knees under an inspection table,
R knee room under the table. they will either twist sideways
R Do not use the space under on their chair, or stand and bend
R the table for shelves or over the table. Both reduce
R storage comfort and so result in
R decreased performance.
R Storage areas below table height
R reduce the ability to visually
R control the contents of the
R inspection booth

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R Reading Provide a magnifier of Confirmation of some indications,

R sufficient power that is particularly small ones, requires
R easy to use so that magnification to see the
R indications can be checked morphology of the indication. For
R under white or UV light. A example under magnification a

R good magnifier is 5X to 10X, scratch is distinguishable from a
R with as much eye relief as crack.
R possible. Convenience is essential to
R An alternative is a encourage the inspector to use
R magnifier attached to the the magnifier on all indications.
R inspectors glasses, which Good eye relief allows the
R can be swung into the line inspectors to view the indication
R of vision as needed with less postural difficulty.
R Magnifiers attached to glasses
R (e.g. as used by dentists) are
R perhaps the most convenient in
R use
R Reading Place swabs, solvent, Placing items conveniently causes

R Non-aqueous wet developer minimum disruption to the search
R and magnifying lamps where process and ensures full coverage
R they can be reached and used of component.
R easily during inspection If items are conveniently
R located, they are more likely to
R be used every time they are
R needed
R Reading Design hanger and suspension The easier it is to move the

R system for easy vertical component vertically, the less
R movement extreme postures will be needed
R Example: Balance hoist for to inspect it fully. This helps
R instant positioning ensure full inspection coverage
R Reading Provide a well designed job A good work card will define the
R aid such as a work card for inspection level and any special
R each component. use of solvent or non-aqueous wet
R Example: Work cards with developer.
R details of component A good work card can capture
R nomenclature, places where inspection knowledge from a
R defects are most likely and variety of sources to allow
R past defect history of these inspectors to develop better
R components. This can be done search patterns and defect
R via paper copy or computer expectations
R program

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R Reading Design reporting system to Standard and comprehensive

R identify defect in reporting reducing errors in
R sufficient detail interpretation of indications and
R Example: Standards for ensures better final decisions.

R making defect location or If reporting is inconvenient,
R component and convenient e.g. insufficient space on form
R means to explain indication or computer field to explain
R to subsequent stages indication, inspector will have
R to curtail the explanation,
R affecting decision accuracy
R Reading Train inspectors to use the Swabbing with approved solvent

R wipe off technique on all effectively removes penetrant
R indications, which could from large areas. When penetrant
R conceal a crack is removed, a crack could be
R revealed beneath the penetrant;
R bleeding back will confirm the
R indications as a crack rather
R than surface contamination
R Reading Train inspectors to wait for A crack indication will not

R the minimum specified time reappear instantly. As time
R interval after swabbing with elapses, any true indication will
R solvent, as part of the wipe become stronger as penetrant
R off technique, for any bleeds back towards the surface.
R indication to bleed and Inspectors often underestimate
R reappear the time needed for a crack
R indication to fully bleed back
R Reading Train inspectors to allow A crack indication will not

R sufficient time for re-develop immediately. Often
R non-aqueous wet developer several minutes are required for
R applied to an indication to full development to render crack
R fully develop. Mark the adequately visible.
R correct development time Inspectors tend to underestimate
R prominently on the the time required for
R non-aqueous wet developer re-development. Alternatively,
R container visual search of new areas is
R continued during re-development,
R leading to memory errors
R concerning inspection coverage
R Reading Provide easily attached Allows consistent positioning of

R holder or hanger for UV light for each circuit of a
R portable UV light for when rotating component.
R both of the inspectors hands Allows inspector to use solvent,
R are needed for other tasks swabs, magnifying lenses while
R still holding component in
R correct position

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R Reading Parts having instances of Instances of high background

R high background should be should be investigated. Parts
R cleaned and undergo full should not receive local cleaning
R penetrant reprocessing by solvent.
R To remove a high background

R condition, the part should be
R cleaned and receive a controlled
R process
R Reading Provide attachment on Frees one of inspectors hands for

R component hanger to stop other tasks.
R component swinging during Encourages inspector to move
R inspection. around component to obtain best
R Example: Quickly attached visibility of indications in
R clamp to booth structure, or different areas
R even good hand grip on
R holder
R Reading Always use swabs (e.g. Swabs provide the correct amount
R Q-tips) when applying the of solvent. Too much solvent can
R wipe off technique. Always be applied if sprayed or washed
R throw away swabs after on, reducing visibility of
R single use cracks, particularly small
R cracks.
R A clean swab each time prevents
R spreading of penetrant which can
R potentially conceal indications

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R Guidelines for component preparation prior to penetrant inspection
R Typical processes applied to engine run components prior to NDT inspection
R Fig.70-00-00-990-210-001

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R Guidelines for the assessment of components by fluorescent penetrant inspection

R Fig.70-00-00-990-210-002

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R Water washable fluorescent penetrant

R Fig.70-00-00-990-210-003

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R Post emulsified fluorescent penetrant
R using water based (hydrophilic) penetrant removers
R Fig.70-00-00-990-210-004

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TSD
WATER-WASHABLE FLUORESCENT PENETRANT INSPECTION

TASK 70-00-00-200-213 Overhaul Process 213 - Water-washable

Fluorescent Penetrant Inspection
This operating procedure has been incorporated into TASK 70-00-00-200-210.

R Fuorescent Penetrant Inspection.
R SUBTASK 70-00-00-230-213-001
R 1. Processing - General Application Penetrant Procedure
R A. Refer to TASK 70-00-00-200-210 ( O.P. 210) SUBTASK 70-00-00-230-210-001.
R SUBTASK 70-00-00-230-213-002
R 2. Processing - Local Application Penetrant Procedure
R A. Refer to TASK 70-00-00-200-210 ( O.P. 210) SUBTASK 70-00-00-230-210-002.

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COLD FERRIC CHLORIDE ETCH

TASK 70-00-00-200-214 Overhaul Process 214 - Cold Ferric

Chloride Etch
SUBTASK 70-00-00-860-214-051
1. Materials Used in this Process
OMat 119 Sodium carbonate (Na2CO3)

OMat 123 Ferric chloride (FeCl3(H2O)6)
OMat 123A Ferric chloride (anhydrous) (FeCl3)
OMat 124 Hydrochloric acid (HCl)
OMat 129 Ammonium hydroxide (NH4OH)
OMat 135 Methylethylketone (M.E.K.) (CH3COC2H5)
OMat 150 Acetone (CH3)2CO)
OMat 173 Alkali deruster
OMat 1/242 Ammonium carbonate ((NH4)2CO3)
SUBTASK 70-00-00-860-214-052
2. Materials Used in the Control of Solutions

OMat 1/63 Indicator
OMat 1/93 Potassium iodide (KI)
OMat 1/99 Sodium thiosulphate (Na2S2O3)
OMat 1/100 Starch (soluble)
SUBTASK 70-00-00-180-214-001
3. Details and Control of the Solution

lists of materials used in this process.
B. Refer to SUBTASK 70-00-00-860-214-053 for safety precautions.
C. Etch solution composition:
Alternative solutions may be used if detailed in the relevant Engine

Manual.
OMat 123A Ferric chloride - 250 to 300 g./litre.

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Dec. 1/95
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OMat 124 hydrochloric acid - 100 to 120 g./litre.
The approximate make-up for 5 litres of solution is:
OMat 123 ferric chloride - 2,5 kg

OMat 124 hydrochloric acid - 1750 ml.
Water - 1700 ml.
NOTE: It is known that impurities in the form of arsenic, molybdenum and

sulphur in the etching solution can accumulate to an amount that
will prevent a satisfactory etch. Therefore, rubber containing a
high percentage of sulphur must not be used for jigs, tank linings
or baskets.
A grade of ferric chloride containing the lowest possible amount of

arsenic should be chosen for making up the solution. Build-up of
molybdenum (which is a constituent of some blades) should be avoided
by frequent renewal of the solution.
The solution should be scrapped and renewed when 6,000 sq.in. of

surface /5 litres of solution have been processed, therefore it is
recommended that the tank size is just adequate for the quantities
of parts being processed.
D. Analyse for ferric chloride (anhydrous) content.
(1) Pipette a 20 ml. sample of the etching solution into a 200 ml. flask
and dilute to 200 ml. with distilled water.
(2) Pipette 20 ml. of the diluted sample into a suitable beaker.
(3) Add approximately 0.5 g of OMat 1/93 potassium iodide and titrate with
N/10 sodium thiosulphate (prepared from OMat 1/99 sodium thiosulphate)
carefully until a pale straw colour is obtained.
(4) Add a few drops of starch solution (prepared from OMat 1/100 starch)
which will give the solution a blue colour; continue titration until
the blue colour is destroyed. The following will then apply:
1 ml. of N/10 sodium thiosulphate = 0.00558g. of iron
Titration value x 8.119 = g./litre ferric chloride (anhydrous)
Hydrochloric acid in ferric chloride (anhydrous)
g./litre ferric chloride (anhydrous) x 0.674 = g./litre combined

hydrochloric acid

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E. Analyse for free hydrochloric acid.
(1) Pipette 20 ml. of the diluted sample, prepared in D.(1) in to a

suitable beaker.
(2) Add a few drops of OMat 1/63 indicator and titrate with N OMat 157
sodium hydroxide until a permanent pink colour is obtained while the

solution is being stirred. The following will then apply:
1 ml. N sodium hydroxide = 0.0365 g. of hydrochloric acid
Titration value x 18.25 = g./litre total hydrochloric acid
Total hydrochloric acid - combined hydrochloric acid from ferric

chloride (anhydrous) = free hydrochloric acid.
SUBTASK 70-00-00-860-214-053
WARNING: 1. PROTECTIVE CLOTHING, RUBBER GLOVES AND GOGGLES MUST BE WORN TO

PREVENT SOLUTION CONTACTING EYES OR SKIN.
2. EYE SPLASHES MUST BE TREATED IMMEDIATELY BY PROLONGED WATER

IRRIGATION FROM THE EYE-WASH BOTTLES PROVIDED, AND REPORT FOR
IMMEDIATE MEDICAL TREATMENT.

RUNNING WATER.
4. ALL BURNS, HOWEVER SLIGHT, MUST BE TREATED AT THE NEAREST

FIRST-AID POST. THE SURGERY OR FIRST-AID POST MUST BE TOLD WHICH
SOLUTION (I.E. THE ACIDS INVOLVED) CAUSED THE BURN.
The health and safety data given are general guidelines in use at Rolls Royce,

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SUBTASK 70-00-00-860-214-054
5. General
Cold ferric chloride etching is sometimes recommended in the Engine Manual

either alone or as one of a series of processes which are used to prepare the

surface of highly stressed parts, such as turbine blades, for inspection. An
even matt surface is produced which reveals inclusions and surface defects,
including faults too small to be seen with the naked eye. There are two
methods of applying the process, by immersion (SUBTASK 70-00-00-110-214-001)
or by swab application (SUBTASK 70-00-00-110-214-A01).
CAUTION: 1. THE PROCESS MUST BE STRICTLY CONTROLLED AND APPLIED ONLY WHEN
ITS USE IS SPECIFIED IN THE ENGINE MANUAL FOR A PARTICULAR PART
AS THE FATIGUE STRENGTH OF THE MATERIAL CAN BE SERIOUSLY REDUCED
BY INTERGRANULAR CORROSION IF IT IS INCORRECTLY APPLIED.
2. TO AVOID CONTAMINATION WHICH PREVENTS A SATISFACTORY ETCH.

RUBBER USED FOR LINING TANKS, BASKETS OR JIGS MUST NOT CONTAIN A
HIGH PERCENTAGE OF SULPHUR.
SUBTASK 70-00-00-110-214-001
6. Processing - Immersion Etch

NOTE: As the process is normally undertaken as one of a series, specific

preparation of the part is not required, but if any delay between
processes occurs or parts are handled in any way they must be
degreased as described on the following operation.
B. Vapour degrease the part as described in TASK 70-00-00-100-101 or primary

clean TASK 70-00-00-100-102 (O.P.102) or aqueous degrease TASK
R 70-00-00-100-118 (O.P.118). Allow the part to cool to room temperature
before proceeding.
R CAUTION: IMMERSION TIMES AND TEMPERATURES MUST BE STRICTLY FOLLOWED TO AVOID

DAMAGE TO THE PART.
C. Place the parts to be etched in a stainless steel wire basket and immerse
R them in the etching solution, refer to SUBTASK 70-00-00-180-214-001, at a
temperature of 15 to 25 deg.C. (59 to 77 deg.F.) for the time specified in
the Engine Manual.
R NOTE: Alternatively, in hot climates where the ambient temperatures are

R between 25 deg.C. and 30 deg.C. the etching time specified must be
R divided by 2. For temperatures above 30 deg.C. the etching time
R specified must be divided by 4.

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D. Remove the parts from the etching solution and wash them thoroughly in the
clean, cold, running water.
R NOTE: Ammonium hydroxide or Ammonium carbonate must be used for parts with
internal passages.
E. Immerse the parts in neutralizing solution consisting of 40 to 60 g./litre

R OMat 119 Sodium carbonate or 10 to 20 g./litre solution of OMat129
R ammonium hydroxide or a 40 - 60 g/l solution of OMat1/242 Ammonium
R carbonate at ambient temperature for 1 - 2 minutes.
R F. Wash the parts in clean, cold water. Thoroughly flush all internal passages
R with clean, cold water.
NOTE: The parts should be kept in water and not allowed to dry before the
next operation.
G. Place a few of the parts at a time into a basket and clean them thoroughly
R using a high-pressure air/water gun or water lance at pressures up to 14
R MPa (2,000psi).
NOTE: A smut can persist on the particular materials QFD, QGE, QEJ and
QDD. If this is the case operations (1) and (2) can be effected on
QFD and QGE materials and operations (3) and (4) on QEJ and QDD
materials.
(1) Immerse QFD and QGE materials in 20 or 30 per cent alkali deruster
(prepared from OMat 173 alkali deruster) for 20 minutes at 60 to 70
deg.C. (140 to 158 deg.F.) or 85 to 95 deg.C. (185 to 203 deg.F.).
R (2) Wash the parts thoroughly in clean, cold water. Flush all internal
R passages with clean, cold water. Pressure wash using an air/water gun
R or pressure wash with a water lance at pressures up to 14 MPa
R (2,000psi) and then proceed to H.
R (3) Immerse QEJ and QDD materials in nitric acid solution at ambient
R temperature as detailed in O.P.122 (TASK70-00-00-100-122 until
R desmutting is complete. This typically takes approximately 30 - 60
R seconds.
R (4) Wash the parts thoroughly in clean, cold water. Flush all internal
R passages with clean, cold water. Pressure wash using an air/water gun
R or pressure wash with a water lance at pressures up to 14 MPa
R (2,000psi) and then proceed to H.
R H. Immerse the parts in clean, hot water at minimum temperature 80 deg.C. (176
deg.F.) then remove and dry using a clean dry air blast.

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SUBTASK 70-00-00-110-214-A01
7. Processing - Swab Etch


R B. Ensure that the part is at ambient temperature.
C. Cold liquid degrease as detailed in O.P.101 (TASK 70-00-00-100-101, SUBTASK

R 70-00-00-110-101-003-A03).
D. Dry the part, using clean, lint-free cloth.
E. Dip a small wad of new cotton wool into ferric chloride etching solution,
refer to SUBTASK 70-00-00-180-214-001.
F. Swab the area of the part requiring etching with the cotton wool pad,
R maintaining a film of solution on the surface for approximately 15 - 45
R seconds or until a slight matt-grey appearance of the machined surface is
observed.
R G. Immediately swab wash the part with clean, cold water to remove the acid.
R Repeat the swab wash with clean swabs until all traces of acid have been
R removed
H. Dry the part by swabbing with OMat 150 acetone or OMat 135 methyl ethyl
ketone.

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FREQUENCY CHECKING OF COMPRESSOR AND TURBINE BLADES

TASK 70-00-00-200-215 Overhaul Process 215 - Frequency

Checking of Compressor and Turbine
Blades
SUBTASK 70-00-00-860-215-053
A. The health and safety data given are general guidelines in use at Rolls
Royce, it is the responsibility of the operator/user to obtain detailed
health and safety data for the materials in use and to refer to local
SUBTASK 70-00-00-860-215-054
2. General
A. Frequency checking of compressor and turbine blades is not a routine

overhaul requirement and should therefore only be used when specifically
instructed. For details of equipment and technique refer to the relevant
repair scheme or modification.
B. The basis of frequency measurement consists of clamping the blade securely

at the root, in the prescribed manner, and inducing the airfoil to vibrate
by the application of external excitation.
NOTE: It is important that the blade be clamped in the specified manner as

clamping can influence the frequency and the position of the nodal
lines.
C. Depending largely upon the localized area of the airfoil at which the
maximum effect of excitation takes place, the blades will vibrate in
accordance with one of a number of possible vibratory patterns, referred to
as modes.
D. Refer to Fig 70-00-00-215-990-001 which shows typical vibratory modes, and

to Fig 70-00-00-215-990-002 to find the node line, it is only necessary to
lightly scatter sand on the blade when it is vibrating; the sand will
either be vibrated off the blade or on to the nodule line as this is a
point of minimum vibration.

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Jun. 1/96
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E. Provided that the source of excitation is not mechanically coupled to the

blade, the resultant vibration will take place at the natural frequency for
whichever mode is induced; this frequency is expressed as a figure
representing the number of cycles per second. The relevant information will
indicate the mode of vibration for which frequency measurement is required,
and the frequency limits to which the blade must conform.

SUBTASK 70-00-00-230-215-001
3. Set Up the Equipment
A. Various methods of frequency checking may be used, with blade excitation

being provided by eddy current or acoustic horn only.
B. A frequency comparator GU18976, GU18976/1 or GU25817 can be supplied by

Rolls Royce Limited and full details of operation and maintenance are
contained in the brochure 0-Rig-GZ976 or O-Rig-GZ817 which is supplied with
the equipment.
C. The resonant frequency of the blade is a function of the blade and clamping
jig as an assembly, and is affected by the applied load and mass of the
fixture. The type of clamp, and the applied load, will be specified in the
appropriate Repair Scheme in the Overhaul Manual, but in general an air
operated 6 in. machine vice has been found to be suitable for a wide range
of compressor blade sizes.
D. The vice should be firmly bolted to a base plate or angle plate, to form an
assembled mass of a recommended minimum of 150 lb (68,2 Kg.) weight; the
maximum weight is determined only by consideration of handling.
E. It is important that the vice and baseplate assembly should not be in rigid
contact with the main structure or bench, otherwise the blade vibration
will be excessively damped. This can be avoided by the inclusion of a
rubber or cork pad or by resiliently mounting the whole assembly on
suitable supports.
F. Before inserting a blade into the vice it must be ensured that the clamping
faces of both the blade root and the vice jaws are absolutely clean and
free from any particles which might prevent the maximum interface contact
from being obtained
NOTE: Some vice jaws require vapor blasting at regular intervals to ensure
a good interface contact and grip of the blade root.
G. All conventional blade types are clamped across two opposite faces of the
root platform or the root block, depending upon the blade size. In some
cases, these are tapered faces and will require specially made vice jaws
with a corresponding degree of taper or swivel taper jaws to cater for a
range of different angles.

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H. Blades with unconventional root locating features may require specially

designed adapters for clamping in the vice but drawings will be supplied if
and when a requirement is established.
I. It is not possible to achieve an adequate clamping load by means of an air

vice on turbine blades and a Rolls-Royce designed fixture is required with
a torque loading screw for applying the load.
J. Before clamping the blade in position, it must be ensured that the

serrations of both the blade root and the jaws are absolutely clean and
free from particles of foreign matter.
K. Most orders of vibration may be excited from the trailing edge of the blade
at varying points depending upon the mode required, and the exciter should
be positioned accordingly. The exciter is designed for continuous
operation, and may remain switched on during the course of a working
session.
SUBTASK 70-00-00-230-215-002
4. Test the Blade
A. Each blade should be placed in the clamp and locked in position for only
sufficient time to observe a stable frequency reading. After testing the
blade is released from the clamp and marked with the frequency figure.
B. Blades that do not meet the required range, within the specified
tolerances, should be rejected and treated as detailed in the Overhaul
Manual.
SUBTASK 70-00-00-230-215-003
5. Check the Equipment
A. On each setting up operation and at every tenth reading the whole system
must be checked by taking a frequency count from a master blade of known
frequency, A master blade will be supplied by Rolls-Royce (1971) Limited to
an overhauling base on request.

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Typical vibratory modes

Fig 70-00-00-990-215-001

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Typical sand patterns

Fig 70-00-00-990-215-002

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ELECTROCHEMICAL QUALITATIVE ANALYSIS

TASK 70-00-00-200-216 Overhaul Process 216 - Electrochemical

Qualitative Analysis
SUBTASK 70-00-00-860-216-051
1. Materials used in the Process
OMat 129 Ammonium hydroxide (NH4OH)

OMat 1/67 Tri-sodium phosphate (Na3PO4 (H20)12)
OMat 1/70 Di-methyl glyoxine
OMat 1/77 Hydrogen peroxide (H2O2)
OMat 1/101 Sodium chloride (NaCl)
OMat 1/102 Sodium fluoride (NaF)
OMat 1/103 Potassium ferro-cyanide (K4Fe(CN)6.(H20)3)
OMat 1/104 Potassium ferri-cyanide (K3Fe(CN)6)
OMat 1/108 Ammonium thiocyanate (NH4SCN)
OMat 1/109 Potassium ethylxanthate
OMat 1/110 Thioglycollic acid (CH2SH.COOH)
OMat 1/111 Dithiol (CH3C6H3(SH)2)
OMat 1/112 Chromotropic acid
OMat 1/113 Potassium thiocyanate (KSCN)
OMat 1/144 Filter paper
OMat 1/156 Hydrochloric acid (HCl)
OMat 1/157 Sulphuric acid (H2SO4)
OMat 1/158 Nitric acid (HNO3)
OMat 1/176 Acetone ((CH3)2CO)
OMat 1/177 Sulphur dioxide (SO2)
OMat 1/178 Cacotheline (C22H23N3O7)
OMat 5/67 Aluminium oxide abrasive paper
SUBTASK 70-00-00-860-216-052
The health and safety data given are general guidelines in use at Rolls-Royce,

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SUBTASK 70-00-00-860-216-053
3. General
This process describes tests used to assist in identifying certain materials

by determining the presence or absence of known constituents

electrochemically, using a portable electrograph.
The portable electrograph kit, Fig.70-00-00-990-216-003, consists of a

carrying case approximately 6.5 x 17in. which houses the battery, the reagent
solutions, test papers, the electrograph and electrical leads. The case
incorporates an indicator lamp.
The electrograph consists of a Tufnol rod, approximately 5in. long 1.5in.

dia., bored out to form a tube. Two electrodes, one formed by a stainless
steel rim at the open end of the tube is the anode, and the other an aluminium
plunger, the cathode, is fitted down the centre of the tube and insulated from
the stainless steel rim. The cathode is spring loaded to ensure firm contact
with the sample during test. Electrical leads are connected at the closed end
of the tube.
The power is supplied by a 6 volt, 7 amp./hr. NiFe battery which is housed in

the carrying case.
SUBTASK 70-00-00-860-216-054
4. Processing
A. Refer to SUBTASK 70-00-00-860-216-051 for the materials used in this

process.
B. Refer to SUBTASK 70-00-00-860-216-052 for the safety precaution and SUBTASK

70-00-00-860-216-053 for the general.
C. Prepare the equipment
(1) It is recommended that new users of this equipment should carry out a
series of practice checks with known materials to gain experience.
CAUTION: 1. THE EQUIPMENT MUST BE HANDLED CAREFULLY TO ENSURE THAT THE

ELECTRODES DO NOT BECOME SHORT CIRCUITED BY A CONDUCTIVE
SURFACE WHILST THE CURRENT IS SWITCHED ON. THE INDICATOR
LAMP WILL INDICATE THIS HAPPENING.
2. OPERATERS MUST BE CAREFUL TO AVOID BEING MISLED BY THE

PRESENCE OF A PLATED COATING. FOR EXAMPLE A MILD STEEL ON
WHICH THERE ARE TRACES OF CHROMIUM PLATING WILL GIVE A
POSITIVE REACTION FOR CHROMIUM AND COULD BE MISTAKEN FOR A
STAINLESS-STEEL.

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(2) Check the state of the battery by short circuiting across the cathode
and anode of the electrograph with a suitable conductor. The battery
is in good condition if the indicator lamp glows brightly. If the
light glows dimly or becomes dim within a few seconds the battery
should be recharged or replaced.
(3) At the commencement of each test make an electrochemical check, as

follows:
(a) Degrease the sample by swabbing with cold liquid degreaser O.P.101
(TASK 70-00-00-100-101) and lightly abrade with OMat 5/67 aluminium
oxide abrasive paper before placing on absorbent paper.
(b) Place a circle of OMat 1/144 filter paper approximately 0.75in.

diameter on a cleaned surface of the material to be tested.
(c) Pipette 2 drops of the appropriate solution No.1 (electrolysis) on

to the paper.
(d) Press the electrograph down on to the paper ensuring that the
centre electrode (cathode) only is in contact with the paper and
the outer electrode (anode) is in contact with the sample material.
(e) Switch on the current and note that the lamp glows dimly; this
indicates the passage of current. If the lamp lights-up brightly
it indicates that current is short circuiting between the
electrodes. This is most likely due to misplacement of the
electrograph in that it is not central over the absorbent paper and
the centre electrode is in contact with the metal sample.
(f) All reagents should be made-up by using distilled water unless

otherwise stated.
D. Identification of material
NOTE: 1. The tests which follow are for the identification of particular
materials.
2. At the end of the tests are two tables, Fig.70-00-00-990-216-001

gives a resume of the tests; Fig.70-00-00-990-216-002 indicates
the uses to which these tests may be put.

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E. Test No.1 - Detection of iron
NOTE: 1. This test is intended as a means of differentiating between

ferrous and non-ferrous alloys and was originally devised to
distinguish EAF flame tubes from those in Nimonic 75. It will
not detect traces of iron in non-ferrous alloys.

2. An intense blue colour indicates an iron-base alloy. A brown or
light-blue should be ignored.
(1) Place a test paper on to a cleaned surface of the sample.
(2) Pipette 2 drops of Solution No.1 on to the paper.
(3) Apply the electrode to the sample and ensure that the electrodes are
positioned correctly.
(4) Pass current for 5 seconds.
(5) Remove the test paper and pipette 1 drop of Solution No.2 on to the
surface that was in contact with the sample and observe the colour
change.
Reagents
Solution No.1 OMat 1/101 sodium chloride 5 g., water 100 ml.
Solution No.2 OMat 1/103 potassium ferro-cyanide 2.5 g., OMat 1/104
potassium ferri-cyanide 2.5 g., water 100 ml.
F. Test No.2 - Detection of chromium
This test is suitable for the detection of chromium in ferrous and nickel
alloys when present in amounts of 3 per cent, or more.
(3) Apply the electrograph to the sample and ensure that the electrodes are

Page 4
Dec. 1/95
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(5) Remove the test paper and observe the side of the paper which was in
contact with the sample, a yellow or orange colour indicates chromium.
NOTE: With many steels of low chromium content the test paper remains
completely unaltered and in these circumstances it is wise to
check that the apparatus is functioning efficiently by carrying
out a test on a sample of known chromium content.
Reagent
Solution No.1 OMat 1/102 sodium fluoride 5 g., water 100 ml.
Shake well and allow to settle, decant the clear supernatant liquid for
use.
G. Test No.3 - Detection of nickel
This test is intended for the detection of nickel in ferrous alloys present
in amounts of 0.5 per cent or more. It may also be used for
differentiating between certain types of nickel steel, provided the nickel
contents differ by more than 1 per cent of the total nickel present.
(1) Place a test paper on a cleaned surface of the sample.
(5) Remove the test paper and pipette 1 drop of Solution No.2 on to the
surface that was in contact with the sample and observe the colour
change. The pressence of nickel is indicated by an immediate pink or
red colour.
NOTE: When using this test to distinguish between alloys of differing

nickel content it is advisable to make checks on samples
containing known amounts of nickel.
Reagent
Solution No.1 OMat 1/102 sodium flouride 5 g., water 100 ml.
Shake well and allow to settle, decant the clear supernatant liquid for
use.
Solution No.2 OMat 1/70 dimethyl glyoxime 1 g. disolved in:
OMat 129 ammonium hydroxide 20 ml. then add:

Page 5
Dec. 1/95
TSD
OMat 1/77 Hydrogen peroxide 20 ml., make up to 100 ml. with water.
NOTE: Solution No.2 is unstable and should not be stored, fresh

solution should be made up daily.
H. Test No.4 - Detection of cobalt

This test is especially suitable for differentiating between the
cobalt-containing Nimonic 90 and 95 and the non cobalt-containing Nimonic
alloys. In the absence of copper this test will detect 1 per cent cobalt
in steel and 0.5 to 1.0 per cent in nickel alloys. It is not possible to
detect cobalt in the presence of copper owing to the formation of the
reddish-brown cuprous thiocyanate.
(2) Pipette 2 drops of solution No.1 on to the paper.
(5) Remove the test paper and pipette 1 drop of Solution No.2 to the
surface that was in contact with the sample.
In Nimonics a turquoise-blue colour indicates cobalt, whilst a

reddish-brown colouration suggests copper or iron. If large amounts of
nickel are present a brown stain is formed, but this is not usually
deep enough to interfere with the cobalt detection. When used to
differentiate between EBF and EAW a reddish-brown colour is obtained
with a light turquoise-blue stain beneath indicating the presence of
cobalt.
Reagents
Solution No.1 OMat 1/102 sodium flouride 5 g., water (cold) 100 ml.
Shake well and allow to settle, decant the clean supernatant liquid for
use.
Solution No.2 OMat 1/108 ammonium thiocyanate 5 g., OMat 1/176 acetone
100 ml.
Alternative electrolyte. Solution No.1 is the most satisfactory for

general use, but the following alternative may be used when it is
desirable to employ non-poisonous reagents.

Page 6
Dec. 1/95
TSD
Solution No.1A OMat 1/101 sodium chloride 2 g., OMat 1/67 trisodium
phosphate 5 g., water 100 ml.
NOTE: The alternative electrolyte is not as sensitive as Solution No.1

but will serve to detect the large amounts of cobalt frequently
added to alloys in the Nimonic type; it is not very suitable
for iron-base alloys. In Solution No.2 other water soluble

ketones, aldehydes or alcohols may be used as alternatives to
acetone. When only small amounts of cobalt are involved a blank
check should be carried out on a similar alloy known to be free
from cobalt and a comparison made immediately, as the blue
complex fades within 1 minute and it is not fully revived by
further additions of ammonium thiocyanate solution.
I. Test No.5 - Detection of molybdenum in nickel alloys
This test is used to distinguish nickel alloys which contain molybdenum

from those which do not contain molybdenum.
(5) Remove the test paper and pipette 1 drop of Solution No.2 and 1 drop of
Solution No.3 to the surface that was in contact with the sample.
(6) The presence of molybdenum is indicated by a pink colour which

intensifies on standing.
Reagents
Solution No.2 OMat 1/158 nitric acid 1 vol., OMat 1/156 hydrochloric
acid 3 vol., water 4 vol.
Solution No.3 OMat 1/109 potassium ethylxanthate 5g., water 100 ml.
NOTE: Solutions No.2 and No.3 are not stable and should not be stored
for more than 1 week.

Page 7
Dec. 1/95
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J. Test No.6 - Detection of molybdenum in steels
This test is used to distinguish between Fortiweld (AEB), which contains

molybdenum, and other mild steels such as ACP, ABE and ABH which do not
contain molybdenum.

(4) Pass current for 5 to 10 seconds.
(5) Remove the test paper and pipette 1 drop of Solution No.2 and 1 drop of
Solution No.3 to the surface which was in contact with the sample.
(6) The presence of molybdenum is indicated by a green colour.
Reagents
Solution No.2 OMat 1/156 hydrochloric acid
Solution No.3 OMat 1/111 dithiol 0.2 g., OMat 1/110 thioglycollic acid
0.5 g. disolve in 1 per cent sodium hydroxide solution prepared from
OMat 157 sodium hydroxide 100 ml.
NOTE: Solution No.3 is not stable and should be made up each day.
K. Test No.7 - Detection of titanium
This test is suitable for distinguishing between Nimonic 75 which contains

only a trace of titanium and other types of Nimonic which contain about 2
per cent. The test is less reliable with Nimonic 100 type alloys
containing 0.5 to 2.5 per cent titanium. A faint positive reaction is
given with 0.2 per cent titanium.
(2) Pipette 1 drop of Solution No.1 on to the paper.
(5) Remove the paper and pipette 1 drop of Solution No.2 to the surface
that was in contact with the sample.

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Dec. 1/95
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(6) The presence of titanium is indicated by a salmon-pink colour.
(7) Nimonic 75 gives a very faint colouration.
(8) Nimonic 80 and 90 give a good salmon-pink colouration.

(9) Nimonic 100 type alloys show a more distinct colouration than Nimonic
75 but less intense than Nimonic 80 and 90.
This test is not intended to differentiate between Nimonic 80, 90 and

100; the test for cobalt and molybdenum being more specific for these
alloys. If, because of the shape of the sample, a full size stain
cannot be obtained, the depth of colouring will be correspondingly
reduced and allowance must be made for this.
Reagents
Solution No.1 OMat 1/157 sulphuric acid 1 ml., water 100 ml.
Solution No.2 OMat 1/112 chromotropic acid 0.5 g., water saturated
with OMat 1/177 Sulphur dioxide 100 ml.
L. Test No.8 - Detection of iron in nickel alloys
This test is suitable for the detection of iron in Nimonic alloys when
present in amounts of 1 per cent or more; this is normally sufficient to
distinguish Nimonic 75 from the other alloys, particularly if used in
conjunction with Test No.7.
(5) Remove the test paper and pipette 1 drop of Solution No.2 to the
surface that was in contact with the sample.
(6) A deep red-brown colouration indicates the pressence of iron above

approximately 2 per cent.
This test is made more reliable by comparison with standard stains

obtained at the time of test from known sample of Nimonic 75 and 80
material. The specification for Nimonic 75 quotes 5 per cent maximum
iron content but in practice the iron content is only rarely below 2
per cent.
Reagents

Page 9
Dec. 1/95
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Solution No.2 OMat 1/113 potassium thiocyanate 2.5 g., 5 ml. of 50 per
cent sulphuric acid solution (prepared from OMat 1/157 sulphuric acid),
make up to 100 ml. with water.

M. Test No.9 - Detection of tin plating
This test is suitable for detection and identification of tin plating or

the presence of tin in alloys which contain at least 5 per cent of tin.
(4) Pass the current for 5 seconds.
(5) Remove the paper and pipette 2 drops of Solution No.2 to the surface
which was in contact with the sample.
(6) A purple to blue colouration indicates the presence of tin. If the

base material itself gives a highly coloured spot the purple colour is
often more easily detected as a surrounding fringe after the paper has
been allowed to stand for approximately 1 minute.
Reagents
Solution No.2 A saturated solution in water of OMat 1/178 cacotheline

Page 10
Dec. 1/95
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Summary of tests - table 1

Fig.70-00-00-990-216-001

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Summary of test - table 1

Fig 70-00-00-990-216-002

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Summary of tests - table 1

Fig.70-00-00-990-216-003

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Uses of tests - table 2

Fig.70-00-00-990-216-004

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Uses of tests - table 2

Fig.70-00-00-990-216-005

Page 15
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TSD
Portable electrograph kit

Fig.70-00-00-990-216-006

Page 16
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POST-EMULSIFIED FLUORESCENT PENETRANT INSPECTION USING OIL BASED (LIPOPHILIC)
PENETRANT REMOVERS
TASK 70-00-00-200-218 Overhaul Process 218 - Post-emulsified

Fluorescent Penetrant Inspection using
Oil Based Penetrant Removers
1. Procedure
This process has been deleted, wherever this process is called up in an Engine
Manual use O.P.213 (TASK 70-00-00-200-213) Water-washable Fluorescent
Penetrant Inspection.

Page 1/2
Dec. 1/95
TSD
ULTRASONIC INSPECTION OF ANTI-WICKING HONEYCOMB
BY THE PULSE ECHO TECHNIQUE

TASK 70-00-00-200-219 Overhaul Process 219 - Ultrasonic

Inspection of Anti-wicking Honeycomb by
the Pulse Echo Technique
SUBTASK 70-00-00-860-219-051
1. Materials used in the Overhaul Process
OMat 133 Glycerine

OMat 1054 Turbine oil
SUBTASK 70-00-00-860-219-052
2. Equipment used in the Overhaul Process
A. An ultrasonic unit with an adjustable frequency range up to 10 MHz and a

delay control allowing the use of probes with delay blocks.
B. A single crystal compression wave probe of 5 MHz, 5 mm. diameter, with a

fixed or replaceable delay block, Fig.70-00-00-990-219-001.
C. An International Institute of Welding (I.I.W.) ultrasonic calibration

block, see Fig.70-00-00-990-219-001.
D. A calibration piece made from the same type of materials, in the same
condition and of the same nominal thickness as that of the part. The
calibration piece should include an area of no honeycomb and areas of
unbrazed honeycomb.
E. Any suitable couplant e.g. OMat 133 glycerine or OMat 1054 turbine oil.
F. Equipment capabilities
(1) The ultrasonic unit and probe combination must be capable of being
calibrated from the 5 mm. dimension of the International Institute of
Welding (I.I.W.) calibration block.
(2) The time base must be linear so that the backwall echoes from the 5 mm.
reflector can be made to rise at intervals of 2, 4, 6, 8 and 10, see
Fig.70-00-00-990-219-A02.

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(3) When the echoes are at their maximum amplitude the probe must be at the
central position over the perspex insert. If the probe is not central
over the insert when the maximum amplitude is obtained, it is because
the sound is not leaving the probe or delay block at 90 degrees or the
delay block is out of square. The reason for the non-perpendicular
sound beam should be investigated, corrected or another acceptable

probe used.
(4) If the amplitude of the first and/or second backwall echo from the 5
mm. dimension is less than that of the second and third echoes an
alternative probe or longer delay block is required.
(5) A probe/delay assembly suitable for one type of seal may not be
suitable for another honeycomb combination.
SUBTASK 70-00-00-860-219-053
A. The health and safety data given are general guidelines in use at Rolls
Royce, it is the responsibility of the operator/user to obtain detailed
health and safety data for the materials in use and to refer to local
SUBTASK 70-00-00-860-219-054
4. General
This inspection process uses the contact ultrasonic pulse echo inspection
method for the assessment of braze integrity of anti-wicking honeycomb seal
material to metal carriers.
The method can be used on ring and segmented seals featuring powder or tape
brazing alloy when the vacuum furnace process is employed.
The inspection must only be performed by trained personnel experienced in

ultrasonic inspection testing and certificated to the requirements of the
relevant authority. Personnel must also have practice in ultrasonic testing
of honeycomb brazed test pieces. The results of this testing must be compared
with physical and or metallurgical testing of the braze bond condition.
This process is only to be used when specified in the Engine Manual or Repair
Scheme.

Page 2
Dec. 1/95
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SUBTASK 70-00-00-270-219-001
5. Calibrate the Equipment
A. Calibrate the Timebase from the 5 mm. dimension on the I.I.W. Calibration
Block.
(1) Place the probe on the I.I.W. calibration block over the perspex
insert. The signal amplitude should be at the maximum when the probe is
central over the insert.
(2) Rotate the probe 90 degrees and repeat step (1) to ensure that the beam
is normal in both directions. If the probe delay block does not
produce a perpendicular beam reject the probe assembly, see
Fig.70-00-00-900-219-001.
(3) Adjust the first backwall echo from the 5 mm. dimension to rise to half
screen height. If the first/second echo is of less amplitude than the
second and third echoes the probe assembly must be rejected and a
longer delay block is required.
(4) Place the probe on section of the seal that has no honeycomb brazed to
it and is of the same thickness of the area is to be examined. If this
is not possible a test piece of the same material, condition and
thickness may be used.
(5) Adjust the echo amplitudes so that the second backwall echo from the
unbrazed section is full screen height. This is the working
sensitivity, see Fig.70-00-00-990-219-A02 and Fig.70-00-00-990-219-B02.
NOTE: Test frequency of 5 or 10 MHz, short pulse capability or any

other facilities within the ultrasonic instruments that improve
the CRT presentation may be used.
SUBTASK 70-00-00-270-219-002
6. Inspection Procedure
CAUTION: CARE MUST BE EXERCISED AT ALL TIMES TO ENSURE COUPLING BETWEEN THE
PROBE/DELAY BLOCK/WORK PIECE WHEN PERFORMING THIS INSPECTION.

B. Set up the ultrasonic instrument as detailed in SUBTASK

70-00-00-270-219-001.
C. Inspect from the side remote from the honeycomb. The side from which the
test is to be carried out on must be smooth and free from foreign matter.

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D. Scan the surface circumferentially or longitudinally in 3 mm. increments

from the centre.
E. Measure the scan lines from the centre line of the honeycomb. The scan
line at the edge of the honeycomb should be 1,5 mm. from the edge.

F. Check the probe and delay blocks for alignment immediately before and after
the examination of the components. If the alignment check after the
examination proves invalid, the components must be re-examined when the
test equipment has been re-calibrated.
G. Mark up areas of indicated unbrazed honeycomb on the backing member and

assess for acceptance. A typical CRT presentation of brazed honeycomb is
given in Fig.70-00-00-990-219-003. Refer to SUBTASK 70-00-00-270-219-003
for acceptance standards, SUBTASK 70-00-00-270-219-004 for interpretation
and SUBTASK 70-00-00-270-219-005 for detection of brazed conditions.
SUBTASK 70-00-00-270-219-003
7. Acceptance Standards
A. General
(1) This acceptance standard must only be used on ring and segmented seals
using anti-wicking honeycomb. See Fig.70-00-00-990-219-005.
(2) Areas to be ultrasonic inspected will be specified in the relevant

Engine Manual and Repair Schemes.
(3) Local areas of honeycomb which cannot be inspected due to the geometry
of the carrier should be accepted if the adjacent area is 100 percent
brazed. If the adjacent area is unbrazed then these areas must also be
considered unbrazed.
B. Visual inspection areas
(1) Areas to be inspected using X2 to X4 magnification
(a) Honeycomb edge ribbons.
(b) Wicking of the braze media between the honeycomb cell walls
(nodes).
(c) Filling of cells with braze media.
C. Edge ribbons to backing
(1) There must not be more than 20 individual cells unbrazed in any 50 mm.
length or more than 10 of those cells adjoining.

Page 4
Dec. 1/95
TSD
(2) An area of 10 unbrazed cell walls must be separated by a minimum of 4

fully brazed cell walls.
(3) Unbrazed edge cells may appear on axially opposite sides.
(4) A minimum length of 26 mm. either side of the scarf joint must be fully
brazed.
(5) Evidence of wicking up to 25 percent of the node is acceptable.
(6) No single cell must be filled more than 25 percent of the finished
depth with excess brazing alloy.
(7) Local pin hole perforations at node walls are acceptable provided they
do not exceed 5 percent of the total number of welds.
D. Areas of ultrasonic inspection
(1) General core to backing.
(a) Unbrazed areas less than 3 mm. in diameter are acceptable.
(b) No more than one third of the width of the honeycomb may be
unbrazed in any one position.
(c) The maximum length of any unbrazed area must not be more than 15
mm. in any direction.
(d) The distance between any two unbrazed areas must be greater than 25
mm.
(e) No more than 2 unbrazed positions are permitted in any 150 mm. of
circumference of seal.
(f) There must be a continuous braze across the whole seal width for at
least 25 mm. on either side of the scarf joint.
(g) Segmented seals must have a continuous braze at least 25 mm. on

either end of the segments measured from the first complete cell.
Open cells at the end of a segment may be unbrazed.
(h) Loose and ragged pieces of honeycomb at the ends of the segments
must be removed.
(i) Weld erosion at the honeycomb backing interface is permitted but

must be assessed as unbraze and included in the unbraze total.
E. Repair of unacceptable braze areas
(1) If the total area of unbraze honeycomb is greater than 20 percent the
whole part should be completely refurbished in accordance with
instructions given in the relevant Repair Scheme.
Page 5
Dec. 1/95
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(2) Rebrazing to eliminate excessive unbraze is limited to two

applications.
F. Mechanical damage
(1) Any mechanical damage to cell walls must be assessed on its merits.

Refer to Engine Manual for detailed inspection standards.
SUBTASK 70-00-00-270-219-004
8. Interpretation of Brazed Conditions
A. Brazed conditions
Area A indicates a condition where the braze material has formed fillets at
the cell walls and filled the cell floor - Good bond.
Area B indicates a condition where the braze has formed a fillet at the
cell wall but has not covered the cell floor - Good bond.
Area C indicates the braze forming a fillet at the cell wall but not
adhering to the base material - Lack of adhesion.
Area D indicates where the braze has formed a fillet at the cell walls
adhering to the base material but some of this has wicked partway up the
wall and formed balls - Good bond.
Area E indicates where all the braze has wicked up the cell walls and
fillet has not been formed at the cell wall and base material junction -
Lack of adhesion.
Area F indicates no braze visible - Lack of adhesion.
Area G indicates braze forming a fillet at the cell wall and covering the
cell floor but not adhering to the base material - Lack of adhesion.
Area H indicates braze forming a fillet at the cell wall and covering the
cell floor. The braze material is adhering to the base material but a
crack has formed in the braze running parallel to the base material
surface.
SUBTASK 70-00-00-270-219-005
9. Detection of the Brazed Conditions
A. Visually the conditions at areas A, G and H appear the same. Only

Ultrasonic Inspection can highlight the lack of adhesion at G and the crack
at H. The present technique cannot differentiate between G and H.

Page 6
Dec. 1/95
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B. It is possible the Ultrasonic Inspection will show a partial lack of

adhesion at area B, but Binocular Inspection should confirm that there is
adhesion between the braze material and the surface of the segment.
C. Ultrasonic and Binocular Inspection should both detect lack of adhesion at

area C.
D. There is the possibility that in Binocular Inspection it is not possible to

see beyond the braze balls in areas D and E. In this case only Ultrasonic
Inspection can give an answer. D represents a bonded area and E represents
lack of bond.

Page 7
Dec. 1/95
TSD
Calibration block and probe

Fig.70-00-00-990-219-001

Page 8
Dec. 1/95
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Working sensitivity
Fig.70-00-00-990-219-A02

Page 9
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Working sensitivity
Fig.70-00-00-990-219-B02

Page 10
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Typical CRT presentation of brazed honeycomb

Fig.70-00-00-990-219-003

Page 11
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Indications of brazed conditions

Fig.70-00-00-990-219-004

Page 12
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Typical section of honeycomb seal

Fig.70-00-00-990-219-005

Page 13/14
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TSD
ULTRASONIC WALL THICKNESS MEASUREMENT - VIDEO DISPLAY METHOD
D125BJ AND D325BJ UNITS

TASK 70-00-00-200-220 Overhaul Process 220 - Ultrasonic Wall

Thickness Measurement
SUBTASK 70-00-00-860-220-051
1. Equipment and Material
A. Standard equipment
Meccasonic D125BJ high frequency ultrasonic instrument
Meccasonic D325BJ high frequency ultrasonic instrument
Meccasonic 1001Z25 (Blue face) 25MHz focussed immersion probe
Meccasonic MSWB25 water bubbler rig
B. Special tools
HU31291 Slotted wedge test block 1 off
SUBTASK 70-00-00-860-220-052
2. Equipment Used in the Overhaul Process
A. Equipment required
(1) High frequency ultrasonic instrument:
Meccasonic D125BJ or
Meccasonic D325BJ
(2) 25MHz Focussed immersion probe
Meccasonic Blueface probe 1001Z25, unless stated otherwise in the

Engine Manual.
(3) Water bubbler rig to supply a 25 mm. (1in.) water column
Meccasonic MSWB25 bubbler rig, unless stated otherwise in the Engine

Manual.
Page 1
Dec. 1/95
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(4) Calibration pieces to be made from the same material or a material with
the same acoustic velocity as the parts to be tested. These should be
clearly identified with the material type, thickness and under local
calibration control. The calibration piece thickness should be within
the thickness limits of the part to be measured, unless otherwise
stated in the Engine Manual.

(5) HU31291 slotted wedge test block 1 off.
B. Equipment capabilities
(1) An efficient probe/set combination will have a performance such that it

will measure wall thicknesses equal to or smaller than those required
by the relevant Engine Manual.
NOTE: 1. Probes have a limited life which can vary from a few weeks
to several months, probes can therefore deteriorate during
storage and it is good policy to alternate probes in use and
storage.
2. A probe with a satisfactory performance on one instrument

may not be satisfactory on another instrument.
SUBTASK 70-00-00-860-220-053
Roll-Royce, it is the responsibility of the operator/user to obtain
detailed health and safety data for the materials in use and to refer to
local requlations to ensure safe working practice.
SUBTASK 70-00-00-860-220-054
4. General
This inspection process uses the ultrasonic pulse echo method at high
frequencies for the measurement of wall thickness on parts where geometry does
not allow normal measurement to be used.
The inspection personnel should be trained in the use of this equipment and
certified to the requirements of the appropriate regulatory authority.
This process is only to be used when recommended in the relevant Engine

Manual.

Page 2
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SUBTASK 70-00-00-200-220-001
5. Setting up the Equipment
A. Safety precautions
(1) Ensure that the voltage selector at the back of the instrument is
positioned to suit the supply voltage.
(2) Ensure that the instrument is supported on its handle to encourage good
air circulation through the bottom and side vents.
(3) If there is a short circuit of the probe, probe leads or B.N.C.

connector, it will destroy the transmitter resistors. Probes which
have an unknown history should be checked for continuity of circuit.
B. Set up the equipment
(1) Connect the probe lead and the water pump to the instrument.
(2) Fill the water container with 50 mm. (2in.) of water and immerse the
pump in the water.
(3) Connect the water pump to the water tower.
(4) Place the probe in its holder.
(5) Place the water tower over the probe ensuring that the probe has
reached the required water path.
SUBTASK 70-00-00-200-220-002
6. Calibrate the D125BJ Unit
CAUTION: DO NOT ROTATE THE CONTROL FURTHER THAN IS NECESSARY TO SWITCH THE
SET ON, UNTIL 30 SECONDS HAVE ELAPSED. THIS IS TO PREVENT PREMATURE
FAILURE OF THE C.R.T.
A. Switch the set on by rotating the brightness control until the pilot light
illuminates (see Fig. 70-00-00-990-220-001).
B. Set the vertical movement control to the mid setting and push in the x 5
control fully.
C. Set the horizontal movement control to the mid setting.
D. Push in SIGNAL INVERT control.
E. Set the outer THICKNESS control to position 5 and the centre THICKNESS
control to its mid position. Ensure the X 10 control is pushed in on the
centre knob.
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F. Rotate the BRIGHTNESS control to obtain a trace of the required brightness

and focus the trace.
G. If necessary centralise the display with the vertical and horizontal

controls.

CAUTION: ENSURE 15 MINUTES HAVE ELAPSED TO STABILISE THE TEMPERATURE BEFORE
FURTHER CALIBRATION OF THE EQUIPMENT.
H. Adjust FINE SENSITIVITY control to 7.5. This is then locked using the
small tab.
I. Set COARSE SENSITIVITY to position 2.
J. Select CALIBRATE position on interface trigger and turn the IF LEVEL and IF
SENSITIVITY fully anti-clockwise.
K. Rotate DELAY control fully anti-clockwise.
L. Adjust the horizontal control to position initial pulse at extreme left of

screen.
M. Position appropriate calibration piece on top of water tower unit. The

first multiple echo pattern should be observed at approximately mid-screen
on the time base (see Fig.70-00-00-990-220-A02).
N. Pull x 10 inner thickness control.
O. Rotate horizontal control clockwise and identify the initial pulse signal.
Position the start of the trace sweep (not the initial pulse) at the
extreme left of the screen.
P. Rotate DELAY control clockwise - the initial pulse will disappear to the
left, continue rotating until the first multiple echo (front wall echo) is
at the extreme left of screen, but no part of the pattern is off screen
(see Fig.70-00-00-990-220-A02).
Q. Move lever down into first ECHO position, no multiple echoes should be
visible at this stage.
R. Gradually increase IF LEVEL control from zero until echo pattern jumps and
locks on to left of screen (start of trace).
S. Tilt calibration piece to reduce interface echo amplitude and by adjusting

IF LEVEL and IF SENSITIVITY obtain the most stable display possible on the
smallest interface echo.
If difficulties are encountered interface locking the front wall echo to

the start of the trace, check the following: Switch to CALIBRATE mode,
ensure that the front wall echo is:
(1) Not delayed off the start of the trace.

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(2) Within 4 graticules from the start of the trace.
T. Adjust DELAY control if necessary.
U. The effectiveness of the interface lock controls should be noted. If it is

not possible to obtain a stable locked trace with a varying echo amplitude,
by adjustment of the IF LEVEL and IF SENSITIVITY controls, the instrument

must not be used.
V. Select position 2 on the outer THICKNESS control using the centre THICKNESS
control and the horizontal control calibrate screen as required. The video
display shall be calibrated from at least the first and second backwall
echo's. Adjust COARSE SENSITIVITY to produce a first backwall echo at a
half and three quarters screen height.
For general measurement of wall thickness the screen is calibrated such

that 0.100in. of material is 10 cm. or 1 graticule = 0.010in. of material
(Fig.70-00-00-990-220-B02 shows the echo pattern from a 0.05in. slip
gauge), or 2,5 mm. of material is 10 graticules therefore 1 graticule is
0,25 mm..
The function of the horizontal shift control should be noted. The trace
should move smoothly on the C.R.T. if difficulty is encountered in placing
an echo on a given graticule line the instrument must not be used.
SUBTASK 70-00-00-200-220-003
7. Calibrate the D325BJ Unit
A. Switch the set on (see Fig.70-00-00-990-220-001).
B. Set the vertical movement control to the mid setting and push in the
vertical control.
C. Set the horizontal movement control to the mid setting.
D. Set the outer THICKNESS control to position 9 and the centre THICKNESS
control to its mid position.
E. Rotate the BRIGHTNESS control to obtain a trace of the required brightness

and focus the trace.
F. If necessary centralise the display with the vertical and horizontal

controls.
CAUTION: ENSURE 15 MINUTES HAVE ELAPSED TO STABILISE THE TEMPERATURE BEFORE

FURTHER CALIBRATION OF THE EQUIPMENT.
G. Set AMPLITUDE control to position 5 or 6 depending on probe performance and

the centre AMPLITUDE control to its mid position.

Page 5
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H. Select CALIBRATE position on interface trigger button and turn the IF LEVEL
and IF SENSITIVITY fully anti-clockwise.
I. Rotate DELAY control fully anti-clockwise.
J. Rotate the horizontal control clockwise to position initial pulse at

extreme left of screen.
K. Position appropriate calibration piece on top of water tower unit. The

first multiple echo should be observed at mid-screen on the time base
(Fig.70-00-00-990-220-A02).
L. Set THICKNESS control to position 5.
M. Rotate DELAY control clockwise. The initial pulse will disappear to the
left - continue rotating until the first multiple echo is at the extreme
left of screen, but no part of the pattern is off screen
(Fig.70-00-00-990-220-A02).
N. Push IF button into LOCK position. No multiple echoes should be visible at

this stage.
O. Gradually increase IF LEVEL control from zero until echo pattern jumps and
locks on to left of screen (start of trace).
P. Tilt calibration piece to reduce interface echo amplitude and by adjusting

IF LEVEL and IF SENSITIVITY obtain the most stable disply possible on the
smallest interface echo.
If difficulties are encountered interface locking the front wall echo to

the start of the trace check the following. Switch to CALIBRATE mode,
ensure that the front wall echo is:
(1) Not delayed off the start of the trace.
(2) Within 4 graticules from the start of the trace.
Q. Adjust DELAY control if necessary.
R. The effectiveness of the interface lock controls should be noted. If it is

not possible to obtain a stable locked trace with a varying interface echo
amplitude, by adjustment of the IF LEVEL and IF SENSITIVITY controls, the
instrument must not be used.
S. Set THICKNESS control to position 3.

Page 6
Dec. 1/95
TSD
T. Using centre THICKNESS control and the horizontal control calibrate screen
as required. The video display shall be calibrated from at least the first
and second backwall echo's. Adjust AMPLITUDE control to produce a first
backwall echo of half to three quarters screen height.
For general measurement of blade wall thickness the C.R.T. screen is

calibrated such that 0.100in. of material is 10 graticules. For example 1

graticule = 0.010in. of material (Fig.70-00-00-990-220-B02 shows the echo
pattern from a 0.050in. slip gauge) or 2,5 mm. of material is 10 graticules
therefore 1 graticule = 0,25 mm..
The function of the horizontal shift control should be noted. The trace
should move smoothly on the C.R.T.. If difficulty is encountered in
placing an echo on a given graticule line the instrument must not be used.
SUBTASK 70-00-00-200-220-004
A. The inspection shall be carried out on the parts in the areas stipulated by
the relevant Engine Manual.
B. The part to be inspected or the probe should be manipulated by hand to give

the maximum echo amplitude from the backwall, this maximum amplitude should
be maintained during inspection.
It may be necessary to re-adjust the INTERFACE (IF) LEVEL and IF

SENSITIVITY to obtain a stable trace when inspecting components.
C. The thickness shall be measured from the zero graticule line on the video
display to the first vertical peak of the backwall echo. Confirmation may
be made on certain geometries by measuring between the first and second
backwall echos.
A continual check for timebase drift can be made by monitoring the second
backwall echo, this should be at exactly twice the measured wall thickness.
D. The C.R.T. calibration should be checked regularly during inspection using

the appropriate calibration piece.
The ability of the probe/set combination to measure down to the required

wall thickness must be checked using the HU31291 slotted wedge test block 1
off, unless otherwise stated in the Engine Manual. The block is placed on
the water tower at the thick end of the taper, it is then moved over the
tower such that the thickness decreases and the value of the minimum wall
section which can be resolved is noted.
The minimum thickness that can be resolved must be at least 0,05 mm.
(0.002in.) less than the minimum thickness quoted in the appropriate Engine
Manual for the particular part being measured.

Page 7
Dec. 1/95
TSD
E. The acceptance standard is stipulated in the Engine Manual.

Page 8
Dec. 1/95
TSD
High frequency ultrasonic instruments

Fig.70-00-00-990-220-001

Page 9
Dec. 1/95
TSD
C.R.T. displays
Fig.70-00-00-990-220-A02

Page 10
Dec. 1/95
TSD
C.R.T. displays
Fig.70-00-00-990-220-B02

Page 11/12
Dec. 1/95
TSD
RADIOGRAPHIC INSPECTION
TASK 70-00-00-200-221 Overhaul Process 221 - Radiographic

Inspection
SUBTASK 70-00-00-860-221-051
A. Standard Equipment
(1) Standard Radiographic Workshop Equipment.
B. Special Equipment
(1) BS3971 Image Quality Indicator
DIN 54109 Image Quality Indicator
ASME Image Quality Indicator
MIL-STD 453 Image Quality Indicator
SUBTASK 70-00-00-920-221-001
2. Control of Equipment and Materials
A. The equipment must be capable of achieving the required sensitivity and

density standards for the parts to be inspected.
B. Tube voltages of more than 150 kV are not necessary.
C. The densitometer must be calibrated at six monthly intervals and accurate

to within 0.1D. The calibration is carried out by comparing the density
readings from a calibrated film strip against the instrument readings. The
calibrated film strip must be traceable to a recognised national standard
or ANSI PH2-19-1986 and replaced every three years.
D. Film Processing Unit
(1) The film processing unit should be monitored by processing pre-exposed

strips of film at the beginning of each shift and measuring the density
levels achieved. Variations of more than 15 per cent from the film
processing datum must be investigated and corrected.

Page 1
Dec. 1/95
TSD
(2) The pre-exposed film is produced by progressively exposing a film to

different levels of radiation. This is achieved by moving a lead sheet
a set distance down the film cassette between exposures to produce a
film with more than three density levels. The exposure parameters and
the density levels achieved are then recorded as the film processing
datum. Alternatively a step wedge can be exposed or the pre-exposed

film can be purchased from a local supplier.
(3) The exposed film is cut into narrow strips and stored in a light proof
box for a minimum of one week before being used.
E. X-Ray Unit
(1) Each x-ray unit should be monitored for consistency of sensitivity and
density at the beginning of each shift.
(2) This is achieved by radiographing a standard test piece with IQI to a

set technique and comparing the density and sensitivity achieved
against the sample radiograph. Variations of more than 20 percent must
be investigated. Alternatively the first component inspected each day
can be checked for density and sensitivity against the sample
radiographs filed with the relevant technique.
SUBTASK 70-00-00-860-221-052
local regulations to ensure safe working practice.
SUBTASK 70-00-00-860-221-053
4. General
This inspection process uses radiography to detect defects (cracks, porosity,

inclusions etc.) both surface and subsurface during overhaul and repair of
parts.
The inspection personnel must be trained in the use of radiography and

certified to the requirements of the appropriate regulatory authority.
This process is only to be used when recommended in the relevant engine

manual.

Page 2
Dec. 1/95
TSD
SUBTASK 70-00-00-260-221-001
5. Processing

70-00-00-860-221-053 for the general.
B. Prepare the part
(1) Prior to radiographic inspection the part must be clean and free from
all oil, grease or unwanted material.
(2) All primary cleaning must be applied as per the relevant engine manual.
C. Procedure
(1) The radiographic technique shall be established by the user to inspect

the area designated, unless the relevant Engine Manual states
otherwise.
(2) The technique must comprise of sample radiographs, sketches to indicate

the positions of the film/part in relation to the radiation source and
a date sheet which typically contains the following:
(a) Apparatus.
(b) Position of the radiation source in relation to the

film/components.
(c) Angle of beam.
(d) Source to film distance (Sfd).
(e) Kilovoltage.
(f) Tube current.
(g) Exposure time.
(h) Focal spot size
(i) Thickness and type of filters used.
(j) Thickness and type of screens used.
(k) Type of film and size.
(l) IQI's (Image Quality Indicator).
(3) The radiographic film used must be a high contrast fine grain type
unless otherwise specified in the engine manual.

Page 3
Dec. 1/95
TSD
(4) The beam angle must be 90 degrees to the centre of the area under
examination. The area of examination is limited by the ability to
achieve the sensitivity and density at the edges of the area being
examined.
(5) Because of the close fitment of butt welds and the defects that can

arise, it is important that the x-ray beam is aligned normal to the
joint face line within 15 degrees. For electron beam welded butt welds
it is more critical that the x-ray beam is normal to joint face line
within 5 degrees. See Fig 70-00-00-990-221-001.
(6) Pipe radiography requires different techniques for different pipe

diameters.
(a) For pipes greater than 44,45 mm. (1.75 in.) inside diameter, use a
single wall technique with at least five exposures per weld
circumference. See Fig 70-00-00-990-221-002. Where the single
wall technique is impractical, use a double wall technique with at
least five exposures per weld circumference. See Fig
70-00-00-990-221-003.
(b) For pipes less than 44,45 mm. (1.75 in.) inside diameter, use a
double wall technique with two exposures at 90 degrees to each
other. See Fig 70-00-00-990-221-004.
(7) All parts must be identified with lead markers which show on the film,
in a position where they do not overshadow the areas being examined.
(8) Place the film in contact with the part and position in such a way that
the required area is examined, ensuring sufficient overlap of the film
is allowed. Lead markers must be used to identify the overlap when the
surface features are not self evident.
NOTE: Multiple film procedures may be used to inspect parts of

variable thickness.
(9) Lead screens must be used for all exposures of 120 kV or more to
decrease scattered radiation. The typical front screen thickness is
0,127 mm. (0.005 in.).
NOTE: Lead screens may be used below 120 kv if required to decrease

scattered radiation, these screens should not exceed 0,05 mm.
(0.002 in.).
(10) The Image Quality Indicator (IQI) sensitivity must be 2 percent or

better for all radiographs unless the Engine Manual states otherwise.
NOTE: IQIs will normally be made of the same material, or

radiographically similar material as the part being inspected.
When this is not possible or when the correct IQI size is
unavailable, IQIs of a less dense material can be used with a
correction factor applied. See Fig 70-00-00-990-221-005.
Page 4
R May. 1/03
TSD
(11) A film/density of between 1.5 and 3 is required for the areas being
inspected, this must include a film fog density of less than 0.3.
(12) The minimum source to film distance (Sfd) and object to film distance
(Ofd) must be adjusted to ensure an unsharpeness (Ug) of less than 0,12
mm. (0.005 in.) for welds and 0,25 mm. (0.010 in.) for all other
applications.
(13) Film processing must achieve consistent results, automatic processing

is recommended.
SUBTASK 70-00-00-220-221-001
A. Inspect the radiographs in a quiet darkened room where the lighting is not
directed towards the inspection eyes or reflecting from the radiographs.
B. Light sources must be capable of finding the differences in film densities

on the radiographs.
(1) A controlled light source or a light box with different levels of

intensity must be used.
(2) Illuminators must produce an even light level over the viewing area,
masking may be used as necessary.
C. Inspect the radiographs for defects, using low power x2 magnifying lenses.
Higher magnification is then used for more detailed examination of local
areas and to assess indications. The acceptance standards given in TASK
70-00-00-300-409, SUBTASK 70-00-00-260-409-001 and TASK 70-00-00-300-414,
SUBTASK 70-00-00-860-414-064, are to be used unless the Engine Manual
states otherwise.
D. A minimum of 10 percent of all radiographs shall be subject to a double

scrutiny, i.e. a separate scrutiny by two radiographers.

Page 5
Dec. 1/95
TSD
Electron Beam Butt Weld - X ray beam alignment

R Fig 70-00-00-990-221-001

Page 6
R May. 1/03
TSD
Pipes greater than 44,45 mm. (1.75 in.) inside diameter

R Fig 70-00-00-990-221-002

Page 7
R May. 1/03
TSD
Pipes greater than 44,45 mm. (1.75 in.) inside diameter

R Fig 70-00-00-990-221-003

Page 8
R May. 1/03
TSD
Pipes less than 44,45 mm. (1.75 in.) inside diameter

R Fig 70-00-00-990-221-004

Page 9
R May. 1/03
TSD
Image quality indicator (IQI) equivalence factors

R Fig 70-00-00-990-221-005

Page 10
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TSD
HONEYCOMB SEAL BRAZE CHECK

TASK 70-00-00-200-222 Overhaul Process 222 - Honeycomb seal

Braze Check
SUBTASK 70-00-00-860-222-051
1. Materials Used in this Process
R OMat 150 Acetone

OMat 1/272 Wetting agent, honeycomb check
OMat 2/7 Wetting agent
OMat 1/285 Wetting agent
NOTE: To identify the consumable materials refer to the Overhaul Materials

Manual (OMat).
SUBTASK 70-00-00-180-222-001
2. Make-up and Control
R A. Two liquids may be used for the honeycomb check. Solution (1) is the
R preferred method for health and safety reasons.
(1) Solution 1
R Solution 1 is an aqueous one containing, OMat 1/272 wetting agent

R honeycomb check at 0.4ml./l.in demineralised water, or OMat 2/7 wetting
R agent at 2g./l. in demineralised water or OMat 1/285 wetting agent at 5
R ml./l. in demineralised water.
The solution is used at room temperature 15 to 25 deg.C.( 60 to 77

deg.F.).
The solution should be kept in a stainless steel tank with a

circulating pump capable of producing a liquid jet to remove trapped
air bubbles from the honeycomb cells.
(2) Solution 2
R OMat 150 Acetone is used as supplied.
R The solution must be kept away from sources of ignitionas it is highly

R flammable.
Page 1
R Nov. 1/03
TSD
B. Control
R (1) At the start of each shift/day, process a known defective honeycomb

R seal to confirm the effectiveness of the test. When the solution
becomes ineffective the solution shall be discarded.

SUBTASK 70-00-00-860-222-052
local regulations to ensure a safe working practice.
R WARNING: 1. SMOKING MUST NOT BE ALLOWED WHEN USING OMAT150 AS IT IS HIGHLY

R FLAMMABLE..
R 2. THE OMAT 150. ACETONE CONTAINER MUST NOT BE INSTALLED NEAR NAKED
FLAMES OR HOT STEAM PIPES.
3. APPROVED EYE PROTECTION, IMPERVIOUS APRON AND PROTECTIVE GLOVES

R SHOULD BE WORN WHEN USING OMAT 150 ACETONE.
SUBTASK 70-00-00-860-222-053
4. General
A. This procedure details a method of inspecting honeycomb braze using a low

viscosity liquid to determine braze joint quality. This process should only
be used on parts when specified in the Engine Manual.
SUBTASK 70-00-00-260-222-001
5. Processing using Solution (1)

70-00-00-860-222-053 for the general.
B. Clean the parts, Refer to TASK 70-00-00-100-102
NOTE: The cleaning is not required if the parts are processed immediately
after brazing and the parts have been kept clean under a clean
plastic sheet.
C. Immerse the parts into solution 1 and pass them through the liquid jet
until all the trapped air bubbles have been removed from the cells.

Page 2
R Nov. 1/03
TSD
D. Remove the parts from solution 1 and stand them on a draining rack for a
minimum of 5 minutes. Seal segments should be stood at an angle of 45
degrees or greater and the seal rings should be laid flat.
E. Examine the parts using natural light supplimented by additional lighting

to provide a minimum light intensity of 500 lux. The solution in full cells
will reflect light from the top of the solution, whereas the empty cells
will not reflect light.
NOTE: Due to the slower draining charactoristics of the aqueous solution,

the bottom 1/3 of the segment or ring does not fully drain and
cannot be inspected. Therefore, it is necessary to turn the parts
over as detailed in re-inspect the parts.
F. Turn the parts over so that the cells which were at the bottom are now at
the top and drain the parts for a minimum of 5 minutes. Examine the parts
as detailed in operation E .
G. Remove the solution from the cells using an air blast.
H. Oven dry the parts at 110 to 120 deg C.( 230 to 248 deg F.) for a minimum
of 15 minutes until the parts are dry.
SUBTASK 70-00-00-260-222-002
6. Processing using Solution (2)

70-00-00-860-222-053 for the general.
B. Clean the parts, refer to TASK 70-00-00-100-101.
NOTE: The cleaning is not required if the parts are processed immediately
after brazing and the parts have been kept clean under a plastic
sheet.
R C. Immerse the parts into solution 2 or fill the cells with solution 2 until
R the cells are full and all the trapped air bubbles have been removed from
the cells.
D. Remove the parts from solution 2 and stand them on a draining rack for a
minimum of 30 seconds at an angle of 45 degrees.
E. Examine the parts using natural light supplimented by additonal lighting to

provide a minimum light intensity of 500 lux. The solution in full cells
will reflect light from the top of the solution , whereas the empty cells
will not reflect light.
R F. Remove the solution from the cells by draining the solution 2 fluid into a
R suitable container and then dry the cells using a clean, dry air blast.

Page 3
R Nov. 1/03
TSD
R G. Allow the seals to dry for 15 minutes.
SUBTASK 70-00-00-220-222-001

NOTE: 1. The definition of a node is an area of ribbon in contact with
another ribbon or on outer edges of honeycomb it is a wall parallel
to double thickness wall.
2. Any region of unbraze defined in one of the following paragraphs

must not coincide with a region of unbraze defined in any other
paragraph.
A. Ring seals, Refer to Fig 70-00-00-990-222-001
(1) Critical areas
(a) Transverse splice position. There must be a continuous braze across

the whole width of seal for at least 25,4 mm ( 1.0 in.) on either
side of splice position in honeycomb core.
(b) Braze adherance of edge ribbon to backing
No more than three consecutive nodes or cell sides shall be

unbrazed in any one position.
The minimum distance between any two unbrazed positions must not be
less than 152,4 mm (6.0 in.), on one edge or one edge relative to
the other.
A maximum of seven unbrazed positions on each ribbon is permitted.
(2) Other areas
(a) The maximum length of any unbraze area must not exceed 12,7 mm.(
0.5 in.).
(b) The maximum width of any unbraze area must not exceed 12,7 mm ( 0.5
in.), or one third of remaining width between the edge ribbons,
whichever is the smaller.
(c) The minimum distance between two unbrazed areas must not be less
than 25,4 mm ( 1.0 in.).
(d) If there are two unbrazed areas within the limits defined under
para A.(1).(b). a circumferential length of 152,4 mm ( 6.0 in.) of
sound braze must be present on each side of defect.
(e) Lack of braze of single wall common to two cells only will not be
considered as a unbrazed area.
Page 4
R Nov. 1/03
TSD
(f) Not more than 25,5 mm .( 1.0 in.) run of unbrazed nodes in any
152,4 mm.( 6.0 in.) length of seal circumference.
(g) Cells must have no more than 25 percent of the final length filled
with excess brazing alloy.
R B. Seal segments, Refer to Fig 70-00-00-990-222-002
(1) Critical areas
(a) Braze adherance of edge ribbon to backing
No more than three consecutive nodes or cell sides shall be

unbrazed in any one segment.
No more than one unbrazed pattern as defined in the previous

paragraph in each segment.
(2) Other areas
(a) The maximum length of any unbraze area must not exceed 12,7 mm (
0.5 in.).
(b) The maximum width of any unbrazed area must not exceed 12.7 mm (
0.5 in.), or one third of remaining width between the edge ribbons
whichever is smaller.
(c) The minimum distance between two unbrazed areas must not be less
than 25.4 mm ( 1.0 in.).
(d) No more than two unbrazed areas are allowed in a segment.
(e) There must be continuous braze at least 25,4 mm ( 1.0 in.) wide
across the whole of the width of the seal at both ends of the seal,
starting from the first row of compleate cells. Open cells at ends
of segments can be unbrazed.
(f) Loose or ragged areas of honeycomb at end of segment are not

permitted.
(g) Lack of braze of single wall common to two cells only will not be
considerd as a unbrazed area.
(h) Not more than one 25,5 mm ( 1.0 in.) run of unbrazed nodes in a
segment.
(i) Cells must not have more than 25 percent of final length filled
with excees brazing alloy.

Page 5
Aug. 1/98
TSD
C. Visual overcheck
(1) Lack of braze can be confirmed by shining a light into the individual
cells, using a fine boroscope or flexible light guide and looking for
light leaking between the honeycomb and backing.

SUBTASK 70-00-00-310-222-001
8. Rework
A. Unless the Engine Manual specifies otherwise , the following rework may be
accomplished on defective honeycomb seal braze.
Re-brazing honeycomb seal to eliminate excessive unbrazed regions is

restricted to two attempts. Total of three brazes in all will be the
maximum permited on any one honeycomb seal. Failure to obtain an acceptable
braze will entail removing honeycomb and repeating repair

Page 6
Aug. 1/98
TSD
R Seal ring - acceptance standards

R Fig 70-00-00-990-222-001

Page 7
Aug. 1/98
TSD
R Seal segment -acceptance standards

R Fig 70-00-00-990-222-002

Page 8
Aug. 1/98
TSD
EDDY CURRENT INSPECTION OF HP TURBINE DISC AIR COOLING HOLES

TASK 70-00-00-200-223 Overhaul Process 223 - Eddy Current

Inspection of HP Turbine Disc Air
Cooling Holes
SUBTASK 70-00-00-860-223-001
A. Standard equipment
R ELOTEST B1 V3 Eddy Current Instrument
R RB211, Trent 700 and 800
Standard Rotor and compliant differential coil rotary eddy current probe
R 7,00 mm (0.275 in.) Rhomann P/N RRP-RUK-RR5-7-47.5
R Standard Rotor and compliant differential coil rotary eddy current probe
R 5,50 mm (0.216 in.) Rhomann P/N RRP-RUK-RR5-5.5-47.5
R Tay 650 and 651
R Standard or Mini rotor and compliant differential coil rotary eddy current
R probe 5,65 mm (0.222in.)
R Rhomann P/N RRP-RUK-RR5-5.65-47.5
R Rhomann P/N MRRP-RUK-RR5-5.65-47.5
R B. Special tools
R All Engine Types
R (RB211-524 and Trent)

R QC6850 Test piece 7,00 mm (0.275 in.) probe 1 off
R (RB211-22B, 535 and Tay)

R QC6851 Test piece 5,50 mm (0.216 in.) probe 1 off

Page 1
R May. 1/01
TSD
SUBTASK 70-00-00-860-223-002
2. Equipment Used in the Overhaul Process
A. Equipment required

R (1) ELOTEST B1 V3 Eddy Current Instrument
R RB211, Trent 700 and 800
R Standard Rotor and compliant differential coil rotary eddy current

R probe 7,00 mm (0.275 in.) Rhomann P/N RRP-RUK-RR5-7-47.5
R Standard Rotor and compliant differential coil rotary eddy current

R probe 5,50 mm (0.216 in.) Rhomann P/N RRP-RUK-RR5-5.5-47.5
R Tay 650 and 651
R Standard or Mini rotor and compliant differential coil rotary eddy

R current probe 5,65 mm (0.222in.)
R Rhomann P/N RRP-RUK-RR5-5.65-47.5
R Rhomann P/N MRRP-RUK-RR5-5.65-47.5
(2) The working test piece can be purchased from Rolls-Royce PLC, Spares
Support Group, Derby.
SUBTASK 70-00-00-860-223-003
Roll-Royce, it is the responsibility of the operator/user to obtain
local regulations to ensure safe working practice.
SUBTASK 70-00-00-860-223-004
4. General
The technique covers the inspection of the HP Turbine Disc Air Cooling Holes
only.
The inspection personnel should be trained in the use of this equipment and
approved in accordance with a training scheme meeting the requirements of
R NAS410, EN4179 or EN473.

Page 2
R May. 1/01
TSD
To maintain a permanent record and ensure repeatability of inspection,

individual Data Cards are to be raised for each instrument/rotary probe
combination used in conjunction with this technique.
This process is only to be used when recommended in the relevant Engine

Manual.
SUBTASK 70-00-00-250-223-001
5. Inspection Procedure Preparation
R A. Refer to Fig 70-00-00-990-223-001, Fig 70-00-00-990-223-002 and Fig

R 70-00-00-990-223-003.
R B. Initial set up Instrument settings ELOTEST B1 V3. All Engine Types
INSTRUMENT SETTINGS
Frequency 500kHz
PreAmp Gain 30 dB Record actual value used
Gain 70/70 Record actual value used
Phase Angle 19 degrees, Record actual value used
FILTER
LPF 1.0kHz
MF/HF/LF Select HF
High Pass ON (800Hz)
Band DYN
HP-Filter 0.80kHz (7,00 mm) Record actual value
used
HP-Filter 0.65kHz (5,50 mm) Record actual value
used
CRT DISPLAY
Y-X/Y-T Y-T
C. Data Card Preparation
(1) Switch on the Elotest B1 V3 instrument ensuring that the green 'power'
LED is illuminated. If the LED is not illuminated the batteries need
recharging, or the power supply has a fault. Allow the instrument to
warm up for 20 minutes.
(2) Data is required according to the following procedure for each new
probe, instrument or rotor combination.
(3) Depress the Frequency button. Then depress the F1 button and using the
thumb wheel on the side of the instrument ensure the frequency is set
to 500 kHz. Depress the F2 button and select the Bandwidth to HF.
Depress the filter and the F4 button and select the Y-X/Y-T switch to
Y-X.

Page 3
R May. 1/01
TSD
(4) Fit the probe to the rotor. Ensure the probe to the instrument cable is
connected to the B1 instrument.
R NOTE: The spring in the compliant tip is easily damaged by over

R travel. Do not depress the tip.

R (5) Depress the Filter button and the F1 button and select the Highpass
R filter to the appropriate setting for the probe diameter on the sample
R data card (kHz) refer Fig 70-00-00-990-223-002.
R Depress the F2 button and select the Lowpass filter to the appropriate
R setting for the probe diameter on the sample data card (kHz) refer Fig
R 70-00-00-990-223-002.
(6) Depress the Gain button and the F2 button and set the PreAmp to 30 dB.
Depress the F3 button and set the Y-Spread to 0 dB. Depress the F4
button and set the X-Spread to 0 dB. Depress the F1 button and set the
Gain to 70/70 dB.
(7) Ensure the Overload LED is not illuminated. If the Overload LED is
illuminated depress the Frequency button then depress the F4 button
which will match the PreAmp gain to the probe. Reset the gain to 70/70
R dB as per para (6) above. (If the Overload LED remains illuminated the
probe may be unserviceable).
(8) The phase angle, filters and sensitivity controls are now to be
adjusted to suit the inspection requirements.
(9) With the display set to Y-X, the phase angle is set by placing the
rotating probe in the hole in the test block over the target depressing
the Phase button and rotating the thumb wheel until the resulting
R figure of eight like signal is vertical. Refer Fig
R 70-00-00-990-223-003.
(10) Select the Y-T display. With the notch in the test block maximized over
the probe coil ensure the amplitude from the notch is set to full
screen height. The filters are correctly set when the target notch
shows as a distinct 'W' shaped sinusoidal signal about the horizontal
centre line.
(11) Adjust the Gain dB control. The sensitivity is correctly set when the
signal from the target rises to full screen graticule height, (4
divisions).
(12) Record all the set up values, on the data card.

Page 4
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SUBTASK 70-00-00-250-223-002
6. Inspection Calibration
A. Refer to Fig 70-00-00-990-223-002, Fig 70-00-00-990-223-003 and Fig

70-00-00-990-223-004.
B. Setting the Inspection Calibration.
(1) Set up the instrument according to the data card for the probe to be
used. Confirm that all items have been set up correctly. Select the Y-T
display.
(2) With the notch in the test piece over the coil path, ensure the phase
angle is set to vertical. If the phase angle is not vertical repeat
B.(1) to ensure that no values have been incorrectly set. If the phase
angle is still incorrect to the data card, the probe should be
exchanged for another until the reason for the change can be
established.
(3) With the notch in the test piece maximized over the probe coil path,
ensure the amplitude from the notch is set to full screen graticule
height. Move the notch away from the coil and then pass the block over
the coil and confirm the set up amplitude is correct.
SUBTASK 70-00-00-250-223-003
A. Refer to Fig 70-00-00-990-223-005, Fig 70-00-00-990-223-006 and Fig

70-00-00-990-223-007.
B. Air Cooling Hole Inspection
(1) There is a requirement to inspect the holes for evidence of cracking.

This may occur at any position down the hole. Evidence of cracking in
the hole, within the area shown in Fig 70-00-00-990-223-006 is cause
for the disc to be rejected from service.
(2) When inspecting the holes use the Y-T display.
(3) Ensure the HP Turbine disc air cooling holes are in a clean condition,
free of loose particulate material and that the probe will pass through
all the holes without damage.
(4) Load the HP Turbine disc onto a turntable fixture with the long drive
arm uppermost and locate the No 1 air cooling hole (situated between
the fir trees 1 and 2).
(5) Lubricate the hole with a small quantity of engine oil to aid the free
running of the rotating eddy current probe.
Page 5
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(6) Adjust the plastic stop collar on the probe to prevent the compliant
tip exiting at the rear of the hole, but ensure the probe coil passes
fully through the hole. The coil can be identified as a small black dot
on the surface of the compliant tip.
(7) Switch on the rotor and fully inspect hole No 1. The rotor should be

set such that the time base sweep starts at the 9 o'clock position of
the hole. As the probe is inserted into the cooling hole two small
signals may be observed merging together at the holes 12 o'clock
position (disc front face). This is normal and is caused by the angle
of the hole relative to the face of the bucket groove.
(8) Following the inspection identify the hole by placing the start point
bucket groove marker in place. Record the inspection result on the
appropriate form.
(9) Leaving the start point marker over hole No 1, inspect hole No 2.
Record the results.
NOTE: The marker is locally manufactured from wire, such that it may
be clipped on the periphery of the disc. Do not place in the air
cooling hole.
(10) Leaving the start point marker in place, position the moving marker
over hole No 2, and inspect hole No 3. Record the results.
(11) Repeat this sequence of events indexing the moving marker along the
bucket grooves to cover the air cooling hole just inspected, leaving
the start marker in place until all the holes are completed.
R (12) RB211, Trent 700 and 800
R During the inspection, visually check the instrument display at the 12

R o'clock and 6 o'clock positions for cracks both in the mouth of the
hole and down the hole. Special attention should be given to the
rearward face of the hole from the 9 o'clock through 6 o'clock, to the
3 o'clock position. Crack indications within this area which exceed the
acceptance criteria are cause for rejection. Indications outside this
area are acceptable.
R (13) Tay 650 and 651
R During the inspection, visually check the instrument display for cracks
R both in the mouth of the hole and down the hole. Cracks may be evident
R at any o'clock position. Crack indications within this area which
R exceed the acceptance criteria are cause for rejection. Indications
R outside this area are acceptable.
(14) Indications with an amplitude in excess of 3 divisions full screen

height are cause for rejection and should be reported.

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(15) When the disc inspection has been completed repeat the inspection
calibration procedure to verify the set up is still valid.
SUBTASK 70-00-00-250-223-004
8. Interpretation of the CRT Screen Display
A. Refer to Fig 70-00-00-990-223-003.
B. Interpretation of the Eddy Current Instrument CRT Screen Display
R (1) RB211, Trent 700 and 800
Defects will be repeatable and show on the Y-T display as a 'W' type
sinusoidal signal rising from the time base as the probe passes over
the defect. Special attention is to be given to the rearward face of
the hole from the 9 o'clock through 6 o'clock to 3 o'clock positions on
the time base. To confirm an indication as genuine, ensure the phase
angle is correct by switching to the Y-X display and viewing the screen
as the probe passes over the defect. This should show a figure of eight
signal rising vertically, starting from the centre spot, as the probe
passes over the crack.
R (2) Tay 650 and 651
R Defects will be repeatable and show on the Y-T display as a 'W' type
R sinusoidal signal rising from the time base as the probe passes over
R the defect. Cracks may be evident anywhere in the bore. To confirm an
R indication as genuine, ensure the phase angle is correct by switching
R to the Y-X display and viewing the screen as the probe passes over the
R defect. This should show a figure of eight signal rising vertically,
R starting from the centre spot, as the probe passes over the crack.
(3) Transient signals can be observed which may look similar to defects.
These will not be reliably or repeatedly observed and there is often a
degree of ringing on, from this type of signal. This type of signal can
be ignored.
SUBTASK 70-00-00-250-223-005
9. Inspection Record
A. Refer to Fig 70-00-00-990-223-007.

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B. Recording of Inspection Results
(1) Bucket groove/air cooling hole positions are defined in relation to

disc fir tree numbers. Fir tree numbers increase in a clockwise
direction when viewed from the rear of the engine, with the fir tree No
1 adjacent to the disc serial number marking. Fir trees, No 1, No 2,

and No 3 are marked as such. The bucket groove/air cooling hole
positions are taken from the preceding fir tree numbers when moving in
the direction of increasing fir tree number, i.e. air cooling hole
position No 1 is between fir tree No 1 and No 2, etc.
(2) For recording purposes and to ensure all holes are inspected, a record
of the inspection results shall be made using a printed form similar to
that shown in Fig 70-00-00-990-223-007. The RB211-22 or RB211-535 HP
Turbine Discs contain 102 holes. The RB211-524 or Trent HP Turbine
Discs contain 92 holes.

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R Elotest B1 V3 eddy current instrument

R Fig 70-00-00-990-223-001

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NDT data card

Fig 70-00-00-990-223-002

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Elotest B1 V3 instrument screen displays

Fig 70-00-00-990-223-003

Page 11
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R QC 6850 and QC 6851 test piece

R Fig 70-00-00-990-223-004

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HP turbine disc air cooling holes

Fig 70-00-00-990-223-005

Page 13
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HP turbine disc air cooling holes rejection areas

Fig 70-00-00-990-223-006

Page 14
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R Fig 70-00-00-990-223-007

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ASSESSMENT OF SURFACE FEATURES USING RUBBER REPLICA MATERIAL

TASK 70-00-00-200-224 Overhaul Process 224 - Assessment of

Surface Features using Rubber Replica
Material
SUBTASK 70-00-00-280-224-001
1. Table of Contents
Materials used in the Overhaul Process SUBTASK 70-00-00-860-224-001

Introduction SUBTASK 70-00-00-280-224-002
Consideration of Measurment Requirements SUBTASK 70-00-00-280-224-003
Application Of Replica Material SUBTASK 70-00-00-280-224-007
Choose the Relevant Replicating Compound
for the Job
Prepare the Surfaces to be Replicated
Prepare the applicator Gun
Apply Replicating Compound to the surface
Remove Replica from the Surface
Examination of Surfaces using Replica SUBTASK 70-00-00-280-224-004
Ensure that the Replica is clean
Assess the Quality of the Replica
Measurement of Feature Depths using Replica SUBTASK 70-00-00-280-224-005
Section the Replica
Measurement of Feature Depth on the
Sectioned Replica
Other considerations from the Replica SUBTASK 70-00-00-280-224-006
Examination
SUBTASK 70-00-00-860-224-001
OMat 150 Acetone ((CH3)2CO)

OMat 1/40 Iso propyl Alcohol
OMat 1/257 Cleaning solvent
OMat 2/168 Rubber Surface Replicating Material

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SUBTASK 70-00-00-280-224-002
3. Introduction
The surface replication materials allow for examination of surfaces with a

resolution better than 0.1 microns. Surface replicating material OMat 2/168

has the flexibility of rubber, which allows it to be used in areas where the
geometry would not permit other "hard-setting" replicas to be extracted. It is
particularly useful for examining surfaces of components in areas that are
difficult to access.
Surface replicating material OMat 2/168 can be used to examine surfaces for
cracking, micro-cracking, impact damage and pitting. It will also replicate
the grain structure at the surface of a polished and etched metal.
This procedure has been written for the measurement by replication of small
surface features on components using an optical microscope. These features
include pitting (corrosion or erosion), indentation damage and impact damage.
The procedure is intended for measurement of features whose depth is greater
than 0,0005 inch(approx. 0.0125mm). The maximum depth that can be measured
depends upon the size of field of view of the optical microscope.
The depth measurements produced are intended for use in the assessment of
damage to components for Technical Variance purposes. The procedure covers
the assessment of requirements of replication, the method for making a
replica, the assessment of the condition of a replica and the method for
taking a measurement from a replica.
SUBTASK 70-00-00-280-224-003
4. Consideration of Measurement Requirements
In making an assessment of the depth of a surface feature on a component it is

important to consider what is to be replicated and measured.
A. Single Impact/Indentation Damage
The feature is the only area of consideration and is automatically

identified as the area to be replicated, measured and reported.
B. Multiple Impact/Indentation Damage
If there are several surface features then these should all be replicated,
measured and reported.All surface features in all differently identifiable
areas of the component need to be assessed separately. ( For example if
there is impact damage on the rim and diaphram of the disc then both areas
must be assessed, not just the deepest of the two).

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C. Many Areas of Impact/Indentation Damage
It can sometimes occur that a very large number of impact marks are made on
a component, for example by repeated contact with a piece of debris. In
this instance it is not feasible to replicate and measure the depth of
every impact mark. A representative sample of what is considered the worst
impact marks should be replicated, measured and all measurements reported.
D. Corrosion/Erosion Pitting
For this type of damage there are usually many surface features and so a
representative sample of the worst (deepest) features needs to be made. A
representative sample will need to be taken for each separately
identifiable area of the component. A visual assessment of the component
will need to be made for each area of the affected component and deepest
features need to be chosen for replication. The replicas made in a
particular area can then be compared using a binocular microscope and the
deepest pits sectioned, measured and reported.
SUBTASK 70-00-00-280-224-003
5. Application of Replica Material.
A. Choose the relevant replicating compound for the Job.
(1) There are two basic grades of OMat 2/168 replica material;
(a) Fluid Replica
This is ideal for replicating fracture surfaces, holes, cavities

and rough surfaces. Its relatively low viscosity allows it to flow
to give good coverage of a surface and to be pumped through a tube
to a remote location if necessary (e.g. the inner surface of a
shaft). With this grade it may be necessary to create a well so
that a suitable amount of fluid is contained above the feature of
interest.
(b) Thixotropic Replica
This grade is useful for replication of features on vertical or

overhead surfaces as it has a higher viscosity than the fluid type.
It does tend to be more susceptible to trapping air bubbles
although this can be minimised by careful application. For areas of
tight geometry the thixotropic may be less useful as there may be
difficulty getting it to the surface to be replicated (e.g. within
very tight holes).

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(2) There are two variants for each of the grades described above.
(a) Normal Setting
This has a setting time of 30 minutes and a working life of 4

minutes at 25 deg. C. The working life is the time that the replica

can be in the applicator tube before it begins to set.
(b) Rapid Setting
This has a setting time of 5 minutes and a working life of 30

seconds at 25 deg. C. The advantage of the rapid setting time needs
to be offset against the need to get the mixed replica onto the
surface in a very short time. If the replica were to be applied
through a long tube to an otherwise inaccessible site then this
type would be unsuitable. It is the usual practice of Rolls-Royce
to employ the normal setting variant for the assessment of damage.
B. Prepare the Surfaces to be Replicated
(1) The surface to be replicated must be clean. It must not be contaminated

with grease, dirt or debris. Replica compounds will only replicate
surfaces with which they come into contact. Grease, dirt and debris
will all prevent contact and will produce artefacts on the solidified
replica.
(2) For the purposes of measuring the depth of corrosion pitting on a

surface a thorough clean of the component must have taken place. The
true extent of the pitting will only be ascertained if all debris is
removed from the pit.
(3) Clean features to be replicated using OMat 150 Acetone, OMat 1/40 Iso
propyl Alcohol or OMat 1/257 Cleaning solvent before applying the
replicating compound to the surface.
(4) To prevent contamination of the replica from fibres remaining from

cleaning cloths, a draught of air (from a compressed air can or a
"blow-brush") can be blown across the surface.
(5) Masking must be applied to the surface surrounding the feature to be

replicated to allow a replica depth of 3-5mm. If the replica depth were
less than this then the replica would be too flimsy to cut and work
with. OMAT 249 Modelling clay has been used successfully for this
purpose on flat surfaces (e.g. diaphragms). Other geometries (e.g.
firtree posts) may allow OMAT 251 Tape adhesive electrical PVC masking
to be effectively used to create a well to contain the replica fluid.
C. Prepare the Applicator Gun
(1) Assemble the applicator gun and cartridge and attach a new mixing
nozzle. Pump the trigger of the gun to prime the replicating fluid
within the nozzle.
Page 4
Oct. 1/02
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(2) The first few millilitres of replica fluid to emerge from the nozzle
must be discarded. Sometimes this initial amount of replicating
material will not contain the full amount of hardener and so will not
solidify properly.
D. Apply Replica Material to the Surface

(1) Apply the replica fluid with a smooth pouring action keeping the nozzle
as steady as possible. This will prevent trapping of air bubbles.
(2) Fill all masked areas to be replicated, completing each one before
moving to the next. It is important to remember that the mixed
replicating fluid has a working life. If the replica remains within the
nozzle for times approaching this working life it will begin to set and
will not produce a good replica of the surface.
(3) After application, the full curing time for the replica must be allowed
to elapse before the replica is pulled from the surface or touched.
Pulling the replica before it is fully cured may give a distorted
replica.
E. Remove Replica From the Surface
(1) Peel the replica away from the surface with a smooth action. The
replica should not tear.
(2) Store the replica in a clear plastic bag to prevent it from becoming
coated in dust.
SUBTASK 70-00-00-280-224-004
6. Examination of Surfaces using Replica
Each replica must be inspected for quality of reproduction. Poor reproductions

due to contamination from dirt, grease, fibres or air bubbles will not be
suitable for measurement
A. Ensure that the Replica is Clean
(1) Microset replica can quickly become covered with dust and fibres when
inspected. This can have the effect of masking small features. If the
replica becomes difficult to examine because of dust or fibres then it
may be washed using a soap solution and rinsed in water. A cool-air
blower can be used to dry off the replica.
B. Assess the Quality of the Replica
(1) A visual assessment of the quality of the replica must be made using a
binocular microscope with magnifications to at least X20.

Page 5
Oct. 1/02
TSD
(2) The feature whose depth is to be measured should be clearly defined on

the replica and must not include air-bubbles or fibres within the body
of the replica at that location. These artefacts can cause local
distortions and make measurements difficult.
(3) If the replica carries any debris that it has removed from the surface

within the feature then the true feature depth will not have been
replicated.
(4) The replica containing the feature to be measured must be clean and as
free from dust.
(5) Previous experience of corrosion pits in Nickel alloys has shown that
the replica will reveal the outline of the grain structure as the grain
boundaries are attacked preferentially during corrosion. This can be
seen using a binocular microscope. The visibility of an outline of a
granular structure on the surface of the feature confirms the
cleanliness of a corrosion pit.
SUBTASK 70-00-00-280-224-005
7. Measurement of Features using a Replica
The depth of a feature (pit, impact damage mark) can be measured by cutting
the replica through the position of maximum feature depth. The resulting
section can then be viewed using an optical microscope and the depth of the
feature measured.
A. Section the Replica
(1) The replica must be examined using a binocular microscope and the
position on the replica that corresponds to the maximum depth of the
feature should be determined.
(2) With the replica placed on a hard flat surface, a sharp, clean scalpel
should be used to slice through the feature at the position that
corresponds to the maximum depth. The scalpel cut should be made as
perpendicular to the surface as possible. This is made easier if the
cut is made whilst viewing through the binocular microscope.
(3) The position of the cut must be reviewed using the binocular
microscope. Both pieces must be viewed. If the slice did not pass
exactly through the deepest part of the feature then the piece with the
deeper part of the feature must be selected for measurement. If the
deepest part of the feature is close to the position of the slice it
will still be visible in profile and suitable for measurement.

Page 6
Oct. 1/02
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(4) The section must be examined to ensure that there are no trapped air
bubbles close to the feature to be measured. Trapped gas bubbles in
this area may cause slight local distortions in the replica and so
affect the measurement being made. If there are such gas bubbles then
the replica should be discarded and a new one made.
(5) A further cut must be made in the replica parallel to the cut passing
through the feature. This will ensure that the replica will sit flat
when measurements are made.
B. Measurement of Feature Depth on the Sectioned Replica
(1) Measurement of the feature depth must be performed on a calibrated

optical microscope. This can be achieved using an optical microscope
fitted with either an eyepiece graticule or a calibrated digital
imaging system.
(a) The replica must be placed on glass microscope slide so that the
section through the feature is uppermost. It is required that the
depth of the feature relative to the level of the component surface
is measured. For this the replica must be correctly aligned to give
an accurate measurement. This can be achieved by placing a ball of
modelling clay between two glass microscope slides and then placing
the replica on the uppermost slide. This will allow the glass slide
to be tilted and so allow the replicated component surface to be
aligned correctly.
(b) The method of correct alignment will depend upon the apparatus used
to view the replica.
If a binocular microscope (variable objective lens) is used then

the replica can be tilted to make the replicated surface of the
component perpendicular to the field of view. The large depth of
field provided by binocular microscopes makes this possible. As the
replica is tilted the replicated surface of the component will
diminish in the field of view until it is just no longer visible -
only the surface of the scalpel cut through the feature will then
be visible. The depth of the feature relative to the component
surface can then be measured.
If an optical microscope (fixed objective lenses) is used then the

method outlined for binocular microscopes above may not be possible
because of the very limited depth of field of view of fixed
objective lenses. For optical microscopes it is preferable to view
the surface made by the scalpel slice and tilt the replica until as
much of that surface is in focus as possible. This of course then
relies upon the scalpel cut being as close as possible to
perpendicular to the replicated surface of the component.

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(c) It should be noted that the error introduced by measuring along a

line that is not perpendicular to the replicated component surface
is not significant for small angles.
For any measurement to be within 10% of the true value the

measurement must be made along a line that is at an angle less than

25 degrees to the line perpendicular to the replicated surface.
This should be easily achievable using the techniques outlined
above
(d) Alignment of the replica must be made at low magnifications. Once

the replica is aligned the magnification must be increased so that
the replicated feature fills as much of the field of view as
possible. It should be noted however that the depth measurement is
to be made relative to the replicated surface of the component.
Consequently the field of view must contain an amount of this
surface sufficient to make the measurement.
(e) The depth of the feature must be measured relative to the

replicated component surface. This can be achieved in two ways:
(i) Using an eye-piece graticule
This is a scale marked onto the eyepiece of the microscope.

The scale needs to be calibrated for each objective lens
setting. Suitable calibration scales are commercially
available for this purpose. These consist of a calibrated
scale etched onto a piece of metal, mounted on a glass slide,
which can be viewed through the microscope. These provide a
convenient method for testing the calibration for every
measurement made. This can also be used for computer based
digital imaging systems.
(ii) Using digital imaging system
It is important that the system is correctly calibrated as for

measurement using an eyepiece graticule. For systems connected
to binocular microscopes with continuously variable objective
lenses each choice of objective setting needs to be
calibrated.

Page 8
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SUBTASK 70-00-00-280-224-006
8. Other Considerations from the Replica Examination

This replication procedure is intended only for the measurement of surface

feature depthbut it does in effect employ a focussed inspection of the damage
using a binocular microscope. Whilst this must not replace any other
inspection requirement (penetrant, visual, binocular) the replica can indicate
the presence of cracks in a surface. Cracks and microcracks will be indicated
on a replica by fine lines (ridges) on the surface of the replica. These
ridges usually vary in height and often carry a fringe of replica material
along their length. They can usually be easily distinguished from scores,
which are usually straight, well defined and of uniform height.
Any unusual feature appearing on a replica, which is not an artefact of the

replication process (trapped fibre, dirt, or gas bubble) should be reported
along with the depth measurements. If an unusual feature is suspected of being
an artefact then the damage can be re-cleaned, replicated and once again
inspected for the unusual feature.
For impact damage marks it is normal for there to be plastic deformation in

the material immediately surrounding the impact point. This can be seen as a
shallow ridge surrounding the impact mark on the metal surface. This ridge is
translated on the replica as a shallow trough surrounding the impact mark.
Evidence of this area of plastic deformation should be reported along with the
depth measurement.

Page 9/10
Oct. 1/02

TSD594-J - Section 2 - Inspection

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TSD

LIST OF EFFECTIVE PAGES

70-00- 70-00- 70-00-

Printed in Great Britain

LIST OF EFFECTIVE PAGES - SECTION 2

OVERHAUL PROCESS 201

MAGNETIC PARTICLE INSPECTION

TASK 70-00-00-200-201 Overhaul Process 201 - Magnetic Particle

1. Materials used in the Overhaul Process

OMat 101 Kerosine

2. Make-up of Magnetic Ink

A. Magnetic ink (fluorescent)

Working concentration 0.1 to 0.5 % OMat608 magnetic ink in OMat1/260

3. Control of Equipment and Materials

A. Refer to SUBTASK 70-00-00-860-201-051 for list of materials used in this

B. Frequency and control of maintenance checks

Ultra-violet (u/v) monitors and white light meters must be calibrated

Pocket field strength indicators, refer to para F.

OVERHAUL PROCESS 201

(2) Six Monthly

Ammeters, refer to para E.

Printed in Great Britain

White light level at inspection area, refer to O.P.210 (TASK

Magnetising units, refer to para J.

Ink fluorescence, refer to para D.

Magnetic ink partical content and contamination, refer to para C.

Process performance test piece, refer to para H.

Tank levels, refer to para I.

Pocket field strength indicaters, refer to para G.

C. Magnetic ink particale content and contamination

The checks should be made as follows;

(2) Allow the sample to settle for 1 hour.

(5) Maintain the particle concentration to the required level by adding

OVERHAUL PROCESS 201

(3) When there is a visible difference in fluorescent brightness between

(1) These should be checked against a calibrated master instrument A max

(2) This is achieved by placing a suitable shunt connected to a digital

F. Pocket field strength indicators

(1) These should be checked against a direct magnetic field of known

G. Process performance test piece

(1) Details of standard test pieces are given in Fig

OVERHAUL PROCESS 201

(3) Monitoring of the performance of equipment, materials and technique is

Printed in Great Britain

Check tank levels and replenish as necessary.

Inspect the condition and functioning of equipment such as ammeters, wander

A. Magnetic particle inspection (MP) is a non-destructive method of detecting

This process describes the various magnetising methods used to detect

Inspection personnel shall be approved by the appropriate regulatory

OVERHAUL PROCESS 201

B. The following abbreviations are those used in the Engine Manual.

CTB= Centralised Treading Bar

OTB= Offset Threading Bar

CFC= Current Flow Clamp (End to End)

CFD= Current Flow Diametrical

AC= Alternating current

FMI=Fluorescent magnetic ink

RMS=Root mean square

OVERHAUL PROCESS 201

(1) Detecting inks consist of finely divided ferro-magnetic particles

Printed in Great Britain

Because the different makes of magnetic particle machines have various

(1) Alternating current (AC).

(2) Half-wave rectified A.C. (HWRAC).