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DOWTY PROPELLERS STANDARD PRACTICES MANUAL

NDT 20DAP
NDT INSPECTION OF COMPOSITE PROPELLERS BLADES AND COMPONENTS

1. Scope

A. This document details the NDT methods to be applied to the production of composite components
including propeller blades, inner sleeves, tube supports etc., it does not include any information on
the inspection of associated metal components, which are covered by separate documents, e.g.
NDT 8DAP Penetrant Flaw Detection. Four methods of NDT are used in the inspection of
composite propeller blades at Dowty Propellers, they are:

(1) Visual Inspection.

(2) Ultrasonic Inspection.

(3) Radiographic Inspection.

(4) Mechanical Impedance Analysis (Acoustic Flaw Detection).

B. The following sections describe the general procedure for each method of inspection, special
calibration requirements, methods of defect assessment and appropriate record keeping.

C. Technicians operating this procedure at Dowty Propellers must be qualified in accordance with the
requirements of NDT 10DAP.

D. A copy of this document must be available to any person operating this inspection procedure.

2. Applicability

A. NDT 20DAP covers the NDT inspection of all composite components manufactured at Dowty
Propellers or by an approved sub-contractor. The requirement to use NDT 20DAP must be made
on the drawing and then quoted on subsequent manufacturing history sheets (MHS) or standard
operational layouts (SOL).

B. As all composite propeller blades are Class 1 items 100% NDT inspection is mandatory.

C. Blades which are to undergo overhaul inspection will be inspected in accordance with techniques
called up in the Standard Practices Manual. These techniques are based upon this document (for
information on calibration only) and will include any special information which is relevant to repair
and overhaul blades.

3. References

A. NDT 5DAP Ultrasonic Flaw Detection.

B. NDT 10DAP Qualification and Certification in Non Destructive Testing.

C. NDT 21DAP Production Acceptance Standards, Composite Blades.

D. NDT 14DAP General Requirements for Radiographic Inspection.

NDT 20DAP

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E. SR 1359P Control of Measuring Equipment (Engineering Development).

F. NDT 24DAP Non Destructive Testing by the Acuostic Flaw Detection Method.

G. NDT 25DAP Contact Ultrasonic Inspection Procedure.

H. NDT 26DAP Immersion Ultrasonic Inspection of Composite Components.

4. Abbreviations

A. FSH Full Screen Height.

B. BWE Back Wall Echo.

C. MIA Mechanical Impedance Analysis.

5. Visual Inspection

A. Equipment.

(1) An illuminated magnifier (x2 or stronger) will be necessary to enhance inspection in some
areas.

B. Procedure.

(1) Prior to any inspection the technician must be familiar with the general make up of a composite
propeller blade, and he/she must be aware of all potential defect areas as shown in NDT
21DAP. It is also important that the technician knows what a standard good blade is, and must
be vigilant to note any new/unrecorded deviations from the standard blade form.

(2) Visual inspection is carried out by all NDT technicians during the course of their normal duties.
Where any doubt occurs as to the acceptability of a visual discontinuity the affected blade must
be rejected, ref para 9.

6. Ultrasonic Inspection

A. The equipment used to ultrasonically inspect composite components can be divided into four
separate sections. Pulse echo inspection of blade aerofoils, through transmission inspection of
blade aerofoils, immersion B-Scan inspection of blade aerofoils and immersion scanning of
composite within outer root sleeve and cylindrical components such as inner sleeves and tube
supports. The following section details equipment and any special calibration requirements.

(1) Pulse Echo Inspection.

(a) Various equipment options are available:-

1 A Panametrics 5227 thickness gauge, coupled to a suitable oscilloscope to act as an

unrectified A-scan display.

2 A Panametrics Epoch II model 2100 digital ultrasonic flaw detector.

NDT 20DAP

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3 A Sonatest Masterscan 330 or 335 digital flaw detector.

4 A Sonatest Powerscan 400 digital flaw detector.

NOTE: All of the above equipment is to be coupled to a Wells Krautkramer KB 450A

or Panametrics M2008 1 inch diameter, 0.5 MHz transducer.

(b) Two general techniques cover all blade types manufactured at Dowty Aerospace Propellers
(P20/1 and P20/4).

(c) Calibration.

1 Calibration of the Panametrics 5227 thickness gauge and probes is done on a

‘calibrate before use’ basis. If the equipment can achieve satisfactory results on the
composite thickness TL series panels then the gauge/probe is said to be calibrated.
The readings required on the composite thickness check panels must be achievable
prior to any set of blade thickness readings being taken.

2 Calibration of the Oscilloscope is to be carried out annually in accordance with SR

1359P.

3 Calibration of the Ultrasonic Flaw Detector is to be carried out in accordance with

NDT 5DAP.

4 Calibration of the composite thickness panels is to be carried out on an annual basis.

(2) Through transmission inspection.

(a) Equipment.
Various equipment options are available:

1 Sonatest UFDS Flaw Detector.

2 Sonatest Masterscan 310D Flaw Detector.

3 Panametric Epoch II model 2100 Digital Flaw Detector

4 Sonatest Masterscan 330 or 335 Digital Flaw Detector

5 Sonatest Powerscan 400 Digital Flaw Detector

NOTE: All of the above equipment is to be coupled to a pair of Sonatest STP 5-1 soft
tip transducers 0.25 inch diameter 1.25 MHz fixed in a suitable calliper
(SE 8373 or similar).

(b) A general technique covers all blade types manufactured at Dowty Aerospace Propellers
(P20/5).

(c) Calibration
Calibration of the ultrasonic flaw detector used for through transmission of composite
propeller blades is to be in accordance with the requirements of NDT 5DAP. Specific
NDT 20DAP

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calibration of the soft tipped probes is not possible, however they must be able to show a
50% FSH or greater signal with less than 15% grass on the thickest section which is to be
inspected. If this cannot be achieved the transducers may be in need of refurbishment.

(3) Immersion B-Scan inspection.

(a) Equipment.
The carbon spars of the propeller blade are examined for ‘Internal Wrinkles’ using an
immersion Ultrasonic B-scan inspection. The equipment used for this is a custom built tank
and ultrasonic system supplied by Ultrasonic Sciences Limited. It enables scanning of the
carbon spars by the immersion method with the transducers fixed in a self normalising
follower. The ultrasonic data is digitised and displayed as a B-scan (cross sectional) image
on the monitor.

(b) A blade specific technique must be raised for this inspection.

(c) Calibration.
Calibration of the whole B-scan system is carried out on a weekly basis. This is achieved
by scanning a calibration piece part No. DAPT 15-0052-00 and viewing/measuring the
produced image for various parameters. Providing all parameters are correct the system is
said to be calibrated.

(4) Immersion C-Scan inspection.

(a) The composite tube section of the propeller within the metal outer sleeve is subject to an
immersion ultrasonic C-scan inspection. The equipment used for this is a custom built rig
made by Meccasonics/USL. It enables scanning to the composite tube by the immersion
method using a 45° mirror to direct sound perpendicularly into the composite. A C-Scan
image is produced on a monitor.

(b) This equipment is also used to examine inner sleeves and tube supports.

(c) Calibration.
Calibration of the whole immersion scanning system is carried out on a weekly basis. This
is achieved by scanning standard test piece No. P20/2T and analysing the resultant scan
as detailed in the technique. As long as the scan is acceptable the system is said to be
calibrated, and no further checks are necessary.

(d) One general technique covers all blade types (P20/9).

(e) Individual techniques are required for other composite components such as inner sleeves
and support tubes.

NDT 20DAP

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7. Radiography

A. Equipment
The equipment in use at Dowty Propellers for radiographic inspection of composite propeller blades
is an Andrex Smart 160W unit capable of producing 120kV at 5mA. All associated equipment and
consumables must meet the requirements of NDT 14DAP.

B. Calibration
All radiographic equipment must meet the requirements of NDT 14DAP.

C. Procedure
X-ray techniques must be raised for each blade type, the whole of the blade planform must be
radiographed and as much as is practical at 90° to the planform working from the root end. The
object of the technique is to ensure adequate coverage and acceptable image quality. A ‘special’
composite image quality indicator is used on composite components, DAPT 15-0081-00.
Additional radiographs may be taken if deemed necessary by the NDT technician to highlight a
suspect area.

8. Mechanical Impedance Analysis - Inspection of Nickel Leading Edge Guard to Blade Bonding.

A. Equipment.
Various equipment options are available:-

(1) MIA 3000/2500 with a P2 or P6 probe (supplied by Staveley).

(2) Bondcheck V95 with a SP probe (supplied by Rohmann UK).

(3) AD-42 1M with a PA-4S probe (supplied by Advanced NDT).

(4) Sonic Bondmaster 1000 with a S-MP-3L probe (supplied by Staveley).

B. A general technique No. P24/1 covers the inspection of all blade types manufactured at Dowty
Propellers.

C. Calibration.

(1) MIA 3000/2500 Electronic calibration of the equipment is required annually in accordance with
the manufacturers instructions.

(2) Bondcheck V95 AD-42-1M and Bondmaster 1000 - calibration is carried out on a ‘Before Use’
basis as described in technique P24/1.

NDT 20DAP

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9. Defect Assessment

A. Any composite propeller blade which shows any discontinuities during NDT examination must be
referred to a Level II or III technician. The Level II or III technician must then assess the
discontinuity against the requirements of NDT 21DAP. If any discontinuities that are unacceptable
to NDT 21DAP, or which are not identified in NDT 21DAP, are found, then the blade must be
rejected. It is the duty of the NDT technician to provide as much information as possible to the
Engineering Department, including where possible, the use of alternative NDT methods. This will
enable assessment of the detrimental effect the discontinuity may have on the operation of the
blade.
All discontinuities and defects must be recorded on the appropriate record sheets as shown in
Appendix 1.

B. Discontinuities found in other components, such as inner sleeves and tube supports, must be
assessed against the requirements of the relevant drawing.

10. Record Keeping

A. Each composite propeller blade which is subject to NDT Inspection must have an NDT 20DAP
record sheet (as shown in Appendix 1) raised. Completed sheets must be stored as inspection
records in the inspection archive in accordance with QMP 25, from where they can be extracted if
required in a subsequent investigation.

B. In addition to the required NDT record sheet, supporting data must be retained, for reference
purposes, of any composite blade feature which does not meet the acceptance criteria. I.e. ‘B’ & ‘C’
scan data is to be saved on compact disc and radiographic data by retaining the relevant
radiographic films.

NDT 20DAP

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APPENDIX 1

NDT 20DAP

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APPENDIX 1 (CONTINUED)

NDT 20DAP

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