Standard Practices Airframe 1. Fluorescent Liquid Penetrant Inspection

Structural Inspection and Repair Manual (Rev D3)
20-00-00 (Rev D3)
STANDARD PRACTICES AIRFRAME

1. Fluorescent Liquid Penetrant Inspection
A. Personnel
(1) The inspection procedures described in this chapter are provided as general information on the subject and are not
intended to substitute for competent training. Should any unusual conditions be found that cannot be resolved locally,
contact Textron Aviation Technical Support for evaluation and possible solutions.
(2) Personnel performing the inspections called out in this manual must meet the requirements as stated in the Introduction
Section of this manual.
B. Processes
WARNING: Increased usage of "high-solids" paint systems has necessitated a revised approach requirement for
stripping of painted surfaces prior to fluorescent liquid penetrant inspection. Remove paint and primer
when specified from area to be fluorescent penetrant inspected. Caution should be exercised as some
paint strippers may contribute to corrosion. All structure adjacent to the area subjected to chemical
stripping solutions should be protected to ensure stripper does not migrate into joints and does not
contact surfaces other than that designated to be stripped. Ensure adequate cleaning of the stripping
solution as this could render the penetrant system inoperable.
NOTE: All components of the penetrant inspection system must be from the same manufacturer and designed
to be used together. For instance, it is not permissible to use a penetrant from one manufacturer and a
cleaner/remover from another manufacturer to inspect the same workpiece.
(1) Fluorescent liquid penetrant inspection is a non-destructive method for finding cracks or other discontinuities that are open
to the surface of solid and essentially nonporous materials. This method utilizes penetrants which fluoresce brilliantly under
ultraviolet (black) light. Indications of damage can be found regardless of the size, configuration, internal structure or
chemical composition of the workpiece being inspected and regardless of the orientation of the damage. The fluorescent
liquid penetrant inspection method has been developed into three basic processing systems characterized by the
penetrant being water-washable, post-emulsifiable or solvent-removable. For the purpose of conducting the inspections
covered in this manual, a solvent removable fluorescent liquid penetrant system such as the Zyglo (registered trade name
of the Magnaflux Corp.) three component kit (Item 2, Table 210, 91-00-00) is recommended. To perform an inspection
using the fluorescent liquid penetrant method, these essential Steps must be followed:
NOTE: Aerosol nonreusable penetrant system is required.
• SURFACE PREPARATION - All surfaces of a workpiece must be thoroughly cleaned with solvent (Item 2, Item 3,
Table 208, 91-00-00) and completely dried before they are subjected to the fluorescent liquid penetrant inspection.
• PENETRATION - After the workpiece has been cleaned, the fluorescent liquid penetrant is applied by aerosol
spray or a brush to form a film of penetrant over the surface being inspected. The film must remain on the
workpiece long enough to allow maximum penetration of the penetrant into any surface openings that may exist. For
applications described in this manual, a minimum of 30 minutes dwell time at a minimum temperature of 60° F is
required.
• REMOVAL OF EXCESS PENETRANT - Optimum removal of the excess penetrant is accomplished by wiping off
as much of the penetrant as possible with a paper towel or a lint-free cloth; then wipe off the remaining penetrant
with a clean cloth slightly dampened with the penetrant system cleaner; and finally, wipe with a dry paper towel or
clean cloth. Do not spray system cleaner directly on the part to clean off excess penetrant. This could cause the
removal of penetrant from any cracks which may be present.
• DEVELOPMENT - The developing agent is applied by aerosol spray to form a film over the surface to be
inspected. The developer acts as a blotter to assist the natural seepage of the penetrant out of any surface
openings and to spread it at the edges to greatly magnify the apparent width of the opening. The developer also
provides a uniform background to assist damage interpretation. Caution should be used in the application of the
developer to provide the optimum coating thickness. If the coating thickness is too thinly applied, the penetrant will
not be spread and a crack or other discontinuity will not be easily detected. If the developer coating thickness is too
thickly applied, the penetrant might not bleed through the coating.
• INSPECTION - After being sufficiently developed, the surface is visually examined for indications of penetrant
bleedout from surface openings. This examination must be performed under suitably darkened conditions for the
penetrant to fluoresce during exposure to ultraviolet light. A model ZB-23A (P/N Magnaflux Corporation) or
equivalent ultraviolet (black) light that meets the following minimum requirements must be used for this inspection:
(1) 3600- to 4200-angstrom wave length, (2) 1000 micro watts per centimeter squared at 15 inches from the
Copyright © Textron Aviation Inc. Page 1 of 29

Retain printed data for historical reference only. For future maintenance, use only current data. Print Date: Tue May 31 15:14:56 CDT 2022
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surface to be inspected.
• POST INSPECTION CLEANING - After completion of the fluorescent liquid penetrant inspection, the inspection
areas must be thoroughly cleaned to remove the developer coating and any remaining traces of the penetrant.
2. Magnetic Particle Inspection
A. Personnel
Personnel performing the inspections called out in this manual must meet the requirements as stated in the Introduction Section
of this manual.
B. Processes
(1) Magnetic particle inspection is a method for locating surface and subsurface discontinuities in ferromagnetic materials
(i.e. materials capable of being magnetized); consequently, non ferromagnetic materials (such as aluminum alloys,
magnesium alloys, copper alloys, lead, titanium alloys, nickel-based alloys such as Inconel and many stainless steel alloys)
cannot be inspected by this method. Magnetic particle inspection is based upon the principle that any discontinuities laying
in a direction generally transverse to the direction of the magnetic field of the part being magnetized for the test will cause
a leakage field to be formed at and above the surface of the part. The presence of the leakage field denoting the
discontinuity is detected by the use of finely divided ferromagnetic particles over the surface of the part. Some of the
particles are magnetically gathered and held by the leakage field to form an outline indicating the location, size, shape and
extent of the discontinuity. In general, magnetic particle inspection utilizes a variety of types of equipment for magnetization
as well as several methods for application of ferromagnetic particles to the test part. Additionally, the ferromagnetic
particles are available in a variety of colors (including fluorescent) and shapes. Magnetic particle inspections required by
this manual can best be accomplished utilizing the wet continuous method on the standard wet-horizontal-type equipment
with either visible or fluorescent magnetic particles suspended in a petroleum-based vehicle (normally kerosene). Since
magnetic particle indications are best obtained when the discontinuity lies in a direction transverse to the magnetic field,
the following procedures are recommended for optimum detection of discontinuities in both bolts and nuts.
WARNING: Improper operation of magnetic particle inspection equipment, because of faulty equipment or by
untrained persons, can jeopardize the airworthiness of parts being inspected. Minute electrical arc
burns caused during the inspection by improper operation of the test equipment can result in
eventual failure of the part.
• Bolts: Inspection of a bolt is accomplished by longitudinal magnetization in a multi-turn low-fill factor coil (i.e. the
inner diameter of the coil greatly exceeds the bolt diameter). For proper magnetization the bolt is positioned close
to the inside coil wall with the bolt length perpendicular to the winding direction. The magnetic particle suspension is
flowed on the bolt and the appropriate current is applied to achieve adequate field strength. Using the described
procedure, laboratory testing has indicated that the ampere turn values listed in Table 201 provide for optimum
detection of discontinuities perpendicular to the bolt axis.
• Nuts: Inspection of a nut is accomplished by circular magnetization on a central conductor (usually a copper rod) the
approximate size of the inside diameter of the nut. For proper magnetization the central conductor bar is inserted
through the nut and the bar is positioned between the heads of the wet horizontal equipment. The magnetic particle
suspension is flowed on the nut and the appropriate current is applied through the central conductor to achieve
adequate field strength. Using the described procedure, laboratory testing has indicated that the amperage values
listed in Table 202 provide for optimum detection of discontinuities parallel to the nut axis.
(2) After magnetic particle inspection, the parts must be carefully demagnetized and cleaned of the ferromagnetic particles.
Carefully check parts for evidence of any possible electric arc burn that may have occurred during the inspection.
Table 201. Magnetic Particle Inspection (Steel Bolts)
Total Bolt Length Including Head To
Bolt Diameter Ampere Turns
Nearest 1/4 Inch
5/8 Inch 2 1/2 Inch 7900
5/8 Inch 2 3/4 Inch 7100
5/8 Inch 3 Inch 6600
3/4 Inch 3 1/4 Inch 7400
3/4 Inch 3 1/2 Inch 6700

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3/4 Inch 3 3/4 Inch 6300

7/8 Inch 3 1/2 Inch 7900
7/8 Inch 3 3/4 Inch 7400
1 Inch 5 Inch 6300
NOTE: Amperage requirement is the ampere turns value divided by the number of turns on the coil. For
example: A 1-inch-diameter x 5-inch-long bolt tested on a 5-turn coil would require 6300 ÷ 5, or 1260
amps.
Table 202. Magnetic Particle Inspection (Steel Nuts)
Nut Size Central Conductor Size Amperage
5/8 Inch 1/2 Inch 500
3/4 Inch 5/8 Inch 600
7/8 Inch 3/4 Inch 700
1 Inch 7/8 Inch 800
3. Eddy Current Inspection
WARNING: This document does not intend to address all of the safety concerns, if any, associated with it's use. It shall
be the responsibility of the users of this document to determine the applicability of any regulatory limitation
before its use, and to establish appropriate health and safety practices.
A. Special Tools and Equipment
(1) Each tool listed in Table 203 is provided as an example of the equipment designed to perform a specific function. Generic
or locally manufactured tools that are the equivalent with respect to accuracy, function, and craftsmanship may be used in
lieu of those listed.
Table 203. Special Tools and Equipment
Item Tool Name Part Number Supplier
Eddy Current Instrument (Phase Nortec 600S Olympus NDT, 48 Woerd Ave.,
1.
Analysis) Waltham, MA 02453
Eddy Current Probe (Barrel Nut 6270 1.55 (B200) Ideal Specialty Co., 2531 E.
2. Hole) 6270-5 1.425 (F90) Independence St., Tulsa, OK
74110-5056
Eddy Current Probe (Barrel Nut 6270-1 1.55 (B200) Ideal Specialty Co., 2531 E.
3. Hole) 6270-6 1.425 (F90) Independence St., Tulsa, OK
74110-5056
Eddy Current Flex Shaft Probe 6270-3 1.68 (B200) Ideal Specialty Co., 2531 E.
4. (Counterbore) 6270-7 1.525 (Model F90) Independence St., Tulsa, OK
74110-5056
Eddy Current Flex Shaft Probe 6270-4 1.68 (B200) Ideal Specialty Co., 2531 E.
5. (Counterbore) 6270-8 1.525 (Model F90) Independence St., Tulsa, OK
74110-5056
Eddy Current Reference 6270-R1 & 6270-R2 (B200) Ideal Specialty Co., 2531 E.
Standard 6270-R3 & 6270-R4 (F90) Independence St., Tulsa, OK
6. 74110-5056
132351 (B200) Beechcraft Wichita, KS
ww2.txtav.com/parts
Eddy Current Instrument Nortec 19e II Olympus NDT, 48 Woerd Ave.,
7.
Waltham, MA 02453

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Eddy current sliding probe 1kHz- SPO3806 1kHz - 10kHz/ order

Olympus NDT, 48 Woerd Ave.,
8. 100kHz, Reflection, 1.5 x 0.8 x PN 9230492
Waltham, MA 02453
1.0 in.
Eddy current probe 100-500 kHz, P/100-500 kHz/A/90.03/6
9. absolute, 90°, 0.03 in. drop, 6 in.
Waltham, MA 02453
long, shielded
Eddy current probe 100-500 kHz, P/100-500 kHz/A/90.75/6
Waltham, MA 02453
long, shielded
0.12 in Bolt Hole Eddy Current BPMD-8-TF Olympus NDT, 48 Woerd Ave.,
11.
Probe Waltham, MA 02453
0.187 in. Bolt Hole Eddy Current BPMD-12-TF Olympus NDT, 48 Woerd Ave.,
12.
0.156 in. Bolt Hole Eddy Current BPMD-10-TF Olympus NDT, 48 Woerd Ave.,
13.
Eddy Current calibration Nortec SPO-3932 Olympus NDT, 48 Woerd Ave.,
14.
Standard Olympus PN 1916915 Waltham, MA 02453
Eddy Current Calibration TB-SI, Stock #1902510
15. Standard Aluminum Block (0.020
Waltham, MA 02453
EDMs)
Bolt Hole Standard 1/8, 3/16, 2024-T6 Aluminum Block Olympus NDT, 48 Woerd Ave.,
16.
5/32 Holes (0.020 EDMs) Waltham, MA 02453
Eddy Current Standard Replacement for EC1006 Locally manufactured (Ref.
17.
Figure 217).
Eddy Current Spot Probe S/300Hz-10kHz/.62 Olympus NDT, 48 Woerd Ave.,
18.
Olympus PN 9213011 Waltham, MA 02453
ET Standard Aluminum Block 2024-T6 Aluminum Block PH Tool 6021 Easton Rd.
(0.020 in. EDMs) Pipersville, PA 18947-1847
VM Solutions Inc. 11208 62ND
Ave E. Puyallup, WA 98373-
19.
4348
NDT Engineering Corp Kent, WA
98032-1115
or make locally per instructions
Eddy current probe 100-500 kHz, P/100-500kHz/A/90.5/6
Waltham, MA 02453
long, shielded
Eddy current probe 100-500 kHz, 6310-90-1/2-1/8 SHLD
Ideal Specialty Co., 2531 E.
absolute, 90°, 0.5 in. drop, 4.5 in.
21. Independence St., Tulsa, OK
long, shielded, with cable and
74110-5056
BNC connector
B. Levels of Technician Qualification
(1) NAS 410, NAS CERTIFICATION AND QUALIFICATION OF NONDESTRUCTIVE TEST (NDT) PERSONNEL, outlines
definitions, general requirements, requirements for qualification, training and experience, examinations and certification for
personnel involved in nondestructive testing. For all training requirements and experience levels, refer to the above
standard.
(2) The following are the seven levels of NDT Qualification:
• Trainee
• Level 1 "Limited"

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• Level 1
• Level 2
• Level 3
• Instructor
• Auditor
(3) The following are the four levels of NDT Certification:
• Level 1 "Limited"
• Level 1
• Level 2
• Level 3
C. Eddy Current General Inspection Procedure
(1) Applicability
This eddy current procedure is for general use for surface inspection to be used in conjunction with specific procedures
contained within this manual, or when an eddy current inspection is warranted, but no other specific inspection procedure
is in effect.
(2) Personnel
Personnel shall be qualified and certified Level 2 or Level 3 in accordance with NAS 410.
(3) Eddy Current Equipment
WARNING: Eddy current equipment must not be operated in areas where combustible gases and vapors are
present.
CAUTION: Eddy current equipment shall not be used in an environment where strong magnetic fields exist,
such as close to large motors, generators, transformers, power lines or welding equipment.
(a) Use the Olympus 500D, Staveley Nortec 19e II, 2000D, Miz 21-B, Phasec 2d or equivalent phase analysis type
equipment.
NOTE: The Olympus 500D was used to establish the procedures in this manual. Only Phase Analysis
Type equipment may be used for inspection.
(4) Probes
(a) Standard shielded absolute surface pencil probe; 1/8 inch, or 1/16 inch diameter, capable of working in the frequency
range of 100 to 500 KHz; straight, 45°, or 90° as applicable for accessibility to the area in which the inspection is to
be performed. Flexible shaft pencil-type probes may be required to gain access to areas requiring inspection.
NOTE: Eddy current diameters for surface inspections shall not exceed 0.125 inch (Ref. Figure 201).
(b) Specialized probes or probes with required characteristics will be identified in the specific procedures.
(c) Eddy current probes and frequencies used for second layer crack detection shall be as specified per specific
procedures.
(5) Reference Standards - Aluminum Standards
(a) Universal Standard NSN 6635-01-092-5129, P/N 7947479-10 or equivalent. Staveley P/N 1920086, NDT Eng. Corp.
P/N SRS-125A, or equivalent with a minimum of a 0.010 inch and 0.020 inch in depth by 0.010 inch maximum width
EDM notch. Staveley P/N 1920086, NDT Eng. Corp. P/N MHS-12-1A-1, or equivalent with a minimum of a 0.020 inch
in depth by 0.010 inch maximum width surface to surface EDM notch in a hole representative of the diameter hole to
be inspected.
(6) Reference Standards - Steel Standards
(a) Universal Standard NRK-3S or equivalent. Staveley P/N NRK-3ST, NDT Eng. Corp. P/N MHS-12-1S-1, or equivalent
with a minimum of a 0.020 inch in depth by 0.010 inch maximum width EDM notch.
(b) Special application reference standards used for specific inspections will be listed in and specified in the specific
procedure.
(7) Surface Preparation
(a) Clean the inspection surface of the component to be inspected with Naphtha (Item 3, Table 208, 91-00-00). Ensure
the inspection surface is free from grease, oil, sealer, loose paint, or any other substance which would prevent an
adequate inspection.

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NOTE: Loose paint shall be removed to allow the eddy current probe to remain in constant contact
with the inspection surface.
(b) All holes requiring bolt hole probe inspections shall be honed with a flex hone or equivalent when the signal to noise
ratio is exceeded. All holes that have been honed should have corrosion protection restored in accordance with the
maintenance manual. At a minimum, the hole shall be cleaned with a cotton swab saturated in naphtha (Item 3, Table
208, 91-00-00) to remove contaminates and debris.
(8) Calibration (Standardization)
NOTE: The operator is to have been adequately trained and be familiar with the equipment used before
performing inspections on aircraft. For instructions on how to operate the eddy current instrument
used, refer to the equipment manufacturer's operation manual.
(a) General Requirements:
• Standardization should be verified at least every 30 minutes. If the original sensitivity requirements are not met
following any standardization verification, all inspections accomplished since the last validated standardization
must be re-accomplished.
• The part to be inspected, calibration standard, inspection unit, and probe must be at ambient temperature to
assure that valid test data is obtained.
• The following instrument settings are meant as a guide, for surface probe inspection. Minor adjustments may
be necessary to optimize the setup; however, the sensitivity level shall be achieved.
• For parts inspected in the painted condition, standardization shall be performed with the equivalent thickness
of non-conductive shim.
• If non-conductive shims are required for lift-off compensation, then the shims shall be placed on the reference
standard during phase adjustment, nulling and establishing sensitivity.
(b) Calibration Procedures
1 Adjust the frequency to the frequency called out in the specific procedure. If no frequency is specified, adjust the
frequency to 200 KHz.
2 Adjust instrument settings to those provided in Table 204 for aluminum components and Table 205 for
ferromagnetic component surface inspections.
3 Place the probe on the reference standard at least 0.25 inch away from the EDM notches and press Null.
4 Repeatedly place the probe on and off of the reference standard, at least 0.25 inch away from the EDM notches
and edges, to produce a lift-off curve. Adjust the Phase Angle to produce a horizontal lift-off curve to the left of
the dot null position.
NOTE: When inspecting ferromagnetic steels and using the High Pass filter, the signal
presentation will result in a positive and negative figure eight response.
5 Place the probe on the reference standard at least 0.25 inch away from the EDM notch and press Null. Scan
over 0.020 inch EDM notch. Adjust the vertical and horizontal gain to achieve, at minimum, a 50% FSH signal in
the vertical direction, and 40% signal in the horizontal directions from the 0.020 inch EDM notch (Ref. Figure
202). For ferromagnetic steels, calibrate to obtain a 50% peak-to-peak signal response from the 0.020 inch
depth EDM notch (Ref. Figure 203).
6 Place the probe on the reference standard at least 0.25 inch away from the EDM notch and press Null. Scan
over the 0.010 inch depth EDM notches to verify that a 20% FSH response from the 0.010 inch deep notch (Ref.
Figure 202).
7 COATING LIFT-OFF COMPENSATION: For inspections performed over painted surfaces, effects from lift-off
caused by the paint thickness affect sensitivity and require compensation for the increased lift-off factor. To
compensate, place the appropriate thickness of non-conductive material (plastic shims) between the probe and
standard during the calibration process. To determine the appropriate thickness of non-conductive shim to be
used during calibration, compare the horizontal position of the dot when placed on the standard, to the position
of the dot when placed on the surface to be inspected. The vertical position of the dot is not of a concern, as the
reference standard and the part under test may have different conductivity values. If the horizontal positions are
within 30% Full Screen Width (FSW), then no compensation is required. If the two horizontal positions are further
than 30% FSW apart, place shims of varying thickness between the probe and the reference standard until the
two positions are within 30% FSW (Ref. Figure 204).

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8 If required, perform Steps 3. thru 6. with the appropriate shims in place.

Table 204. Initial Instrument Settings for Olympus Nortec 500D Surface Inspection of Aluminum
SOFT KEY DESCRIPTION SETTING
FREQ Frequency 200 KHz
H-GAIN Horizontal Gain 65
V-GAIN Vertical Gain 70
ANGLE Angle (Phase) 95 degree
LPF Low Pass Filter 100
HPF High Pass Filter OFF
CONT Cont Null OFF
SWEEP Sweep OFF
Probe Drive Mid
V-POS Vertical Position 20
H-POS Horizontal Position 80
Table 205. Initial Instrument Settings for Olympus Nortec 500D Surface Inspection of Ferromagnetic
Steels
HPF High Pass Filter 2
CONT Cont Null OFF
SWEEP Sweep OFF
Probe Drive Mid
D. Eddy Current Surface Inspections
NOTE: Refer to the EDDY CURRENT GENERAL INSPECTION PROCEDURE prior to performing any of the
specific Eddy Current Surface Inspections listed below. The EDDY CURRENT GENERAL INSPECTION
PROCEDURE describes the equipment, surface preparation and calibration instruction necessary to
perform the EDDY CURRENT SURFACE INSPECTIONS.
(1) General Surface Inspections
NOTE: Special care must be taken by the operator to ensure that the probe's position is perpendicular to
the inspection surface to avoid possible lift-off effects during surface scanning. The ability to hold
the probe in a steady position depends upon the competence and experience of the operator.
CAUTION: When using the High Pass and Low Pass filtering during inspections on ferromagnetic material,
scanning speed is critical to avoid suppression of crack signals. Verify and maintain scanning
speeds established on the calibration standard.
(a) Scan the surface to be inspected. When the direction of cracking is known, scan perpendicular to the direction of the
cracking. Where the direction of the principle loading is known, scan parallel to the load path. Where neither are
known, scan at 0°, 45°, and 90° (Ref. Figure 205). A scanning index shall be selected to ensure complete coverage of
the area to be inspected, 1/2 coil maximum. Re-nulling may be required on the component being inspected due to

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minor variations between the component and the material composition of the standard.
(2) Surface Inspection Around Flush Fasteners
(a) Scan around the entire diameter of the fastener twice. Position the probe's coil immediately outside the edge of the
fastener head. Maintaining a constant, yet minimal distance is required to maintain sensitivity to cracks propagating
from the fastener hole. A circle template made of non-conductive material may be utilized for this to be achieved (Ref.
Figure 206). Re-nulling may be required on the component being inspected, due to minor variations between the
component and the material composition of the standard.
(3) Surface Inspection Around Protruding Fastener Heads
CAUTION: When Teflon tape is applied to the probe tip to protect from wear and reduce probe drag, it shall be
applied in a manner as not to affect the lateral spacing required to maintain sensitivity to cracks
propagating from the fastener hole.
(a) Scan around the entire diameter of the fastener twice, positioning the probe's coil adjacent to, yet in contact with the
side of the fastener. Using the fastener as a guide, maintain a positive pressure against the fastener head to ensure
constant spacing for sensitivity to be maintained for detection of cracks protruding from the fastener head (Ref.
Figure 207). Re-nulling may be required on the component being inspected, due to minor variations between the
(4) Surface Inspection Around Bushings
(a) Scan around the entire diameter of the bushing twice, position the probe's coil immediately outside the edge of the
bushing. Maintaining a constant, yet minimal distance is required to maintain sensitivity to cracks propagating from
the bushing hole. A circle temple or specialized probe guide made of non-conductive material may be utilized for this
to be achieved. Re-nulling may be required on the component being inspected due to minor variations between the
(5) Surface Inspection Of Radii
NOTE: The probe must remain perpendicular to the inspection surface.
(a) Scan the radius in both longitudinal and transverse direction while maintaining the probe perpendicular to the
inspection surface (Ref. Figure 208). A scanning index shall be selected to ensure complete coverage of the area to
be inspected, 1/2 coil diameter maximum. Re-nulling may be required on the component being inspected, due to
minor variations between the component and the material composition of the standard.
(6) Surface Inspections Spar Flange Surfaces
(a) Scan the surfaces including the edges of the forward, vertical, and aft flanges (Ref. Figure 209). A scanning index
must be selected to ensure complete coverage of the area to be inspected, 1/2 coil diameter maximum. Re-nulling
may be required on the component being inspected, due to minor variations between the component and the material
composition of the standard. Cracks will typically start at a fastener hole and move to the nearest edge.
CAUTION: Special care must be taken by the operator to ensure that the probe's position is perpendicular to
the inspection surface to avoid possible lift-off effects during surface scanning. The ability to hold
the probe in a steady position depends upon the competence and experience of the operator.
(7) Surface Inspection Wing Spar Fittings
(a) Scan the surfaces of the wing spar bathtub fittings, inspect the radius surfaces, flat surfaces, depressions,
counterbore radius (washer-face areas), around the wing bolt bore, and counterbore walls of each wing fitting. Focus
extra attention on the feathered edges, counterbore radius, counterbore walls, and the slot in the center section
fittings. Scan at 0°, 45°, and 90°. A scanning index should be selected to ensure complete coverage of the area to be
inspected, 1/2 coil maximum. Re-nulling may be required on the component being inspected due to minor variations
between the component and the material composition of the standard (Ref. Figures 210, 211 and 212).
(b) Scan the forward and aft faces of the exposed lugs and the bolt bore. Pay particular attention to the area around the
wing attach holes. Scan at 0°, 45°, and 90°. A scanning index should be selected to ensure complete coverage of the
area to be inspected, 1/2 coil maximum. Re-nulling may be required on the component being inspected due to minor
variations between the component and the material composition of the standard (Ref. Figures 213).
(8) Surface Inspection of Wing Spar Fittings Using Ideal Speciality Probes
(a) Calibrate in accordance with the CALIBRATION (STANDARDIZATION) procedure using the Ideal Specialty
calibration standard. Ensure Teflon tape is applied to the surface of the probes coil to protect the coil and reduce
probe drag. Slowly rotate the probe through multiple 360° revolutions a minimum of three times for each hole,

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counterbore areas and radius areas that are inspected. Re-nulling may be required on the component being
inspected due to minor variations between the component and the material composition of the standard.
(9) Indication Evaluation for Surface Inspection
(a) Any vertical deflection that is distinguishable (separated) from the background noise and not caused by lift-off or part
geometry shall warrant further examination and scanning of the area of interest.
(b) Mark any repeatable crack-like indications equal or greater than 20% vertical deflections above the baseline/null
point. Any repeatable crack-like indication equal or greater than 20% vertical deflections above the baseline/null point
shall be considered a crack and reported via the reporting instructions.
(10) Acceptance and Rejection Criteria
(a) No cracks allowed. If any evidence of cracks or other discrepancies are found, such as small cracks starting from
rivet holes; hairline cracks in spar caps, sheared or deformed rivets, contact Textron Aviation Technical Support for
consultation.
E. Eddy Current Fastener Hole Inspections
(1) Eddy Current Equipment
WARNING: Eddy current equipment must not be operated in areas where combustible gases and vapors are
present.
NOTE: Eddy current equipment shall not be used in an environment where strong magnetic fields exist,
such as close to large motors, generators, transformers, power lines or welding equipment.
(a) Use Olympus 500D, Staveley Nortec 19e ll, 2000D, Miz 21-B, Phasec 2d, or equivalent phase analysis type
equipment.
NOTE: The Olympus Nortec 500D was used to establish the procedures in this manual.
(2) Probes/Scanner
(a) Standard shielded differential/reflection or absolute manual-type bolt hole probes capable of working in the frequency
range of 100KHz to 2MHz.
(b) Automated fastener hole scanner, with reflection/differential probes capable of working in the frequency range of
100KHz to 2MHz of varying diameter sizes may be used. Operation of the scanner shall be in accordance with the
manufacturers' operation manual.
(3) Fastener Hole Reference Standard - Aluminum Standards
(a) Universal Standard NSN 6635-01-092-5129 P/N 7947479-10, or equivalent. Staveley P/N 1920086, NDT Eng. Corp.
(b) Staveley P/N 1920086, NDT Eng. Corp. P/N MHS-12-1A-1 or equivalent with a minimum of a 0.020 inch in depth by
0.010 inch maximum width surface to surface EDM notch in a hole representative of the diameter hole to be
inspected.
(c) Special application reference standards used for specific inspections will be listed in and specified in the specific
procedure.
(4) Steel Standards
(a) Universal Standard NRK-3S or equivalent, Stavey P/N NRK-3ST, NDT Eng. Corp. P/N MHS-12-1S-1, or equivalent
with a minimum of a 0.020 inch in depth by 0.010 inch maximum width EDM notch.
(b) Universal Standard NSN 6635-01-092-5129, P/N 7947479-10, Steel 4340 or equivalent. Stavey P/N 1920086, NDT
Eng. Corp., Olympus Corp.
(c) Olympus P/N MHS-12-1S-1 equivalent with a minimum of a 0.020 inch in depth by 0.10 inch maximum width surface
to surface EDM notch in a hole representative of the diameter hole to be inspected.
(5) Surface Preparation
(a) Clean the inspection surface of the component to be inspected with naphtha (Item 3, Table 208, 91-00-00). Ensure
the inspection surface is free from grease, oil, sealer, loose paint, or any other substance which would prevent an
adequate inspection.
(b) All holes which exhibit excessive noise during bolt hole probe inspections should be cleaned with a tool such as a flex
hone and re-inspected. At a minimum, the hole shall be cleaned with a cotton swab saturated with naphtha (Item 3,
Table 208, 91-00-00) to remove contaminates and debris prior to inspection.
CAUTION: Holes which have been flex honed, shall have the corrosion protection restored in accordance with

20-00-00 (Rev D3)
the maintenance manual.

(6) General Requirements
(a) Standardization should be verified at least every 30 minutes. If the original sensitivity requirements are not met
following any standardization verification, all inspections accomplished since the last validated standardization must
be re-accomplished.
(b) The part to be inspected, calibrated standard, inspection unit, and probe must be at ambient temperature to assure
that valid test data is obtained.
(7) Manual Fastener Hole Inspections
(a) Manual Fastener Hole Calibration (Standardization)
NOTE: The following instrument settings are meant as a guide, for manual fastener hole inspections.
Minor adjustments may be necessary to optimize the setup; however, the sensitivity level shall
be achieved.
1 Connect the cable and probe to the instrument, and turn the instrument ON. Apply silicone adhesive, Teflon tape
(Item 18, Table 210, 91-00-00) to the probe as required to prevent wear.
2 Adjust the frequency to the frequency called out in the specific procedure. If no frequency is specified, adjust the
frequency to 500 KHz.
NOTE: 200 KHz may be used for absolute probes, if the probe becomes saturated when trying to
obtain the required sensitivity during standardization.
3 Adjust the instrument settings to those provided in Table 206 for Differential/Reflection probes and to Table 207
for Absolute/Bridge probes.
4 Adjust the Horizontal position to 50% FSW and the Vertical position to 50% FSH for Differential/Reflection
probes or 80% horizontal and 20% vertical positions for Absolute/Bridge probes.
5 Insert the probe into the appropriate size hole in the calibration standard which represents the diameter of the
hole to be inspected. A snug fit in the hole without binding is required. Verify the coil is 90° away from the corner
EDM notch and press Null.
6 Position the probe in the hole and repeatedly push the coil side of the probe away from the hole wall to generate
a lift-off response.
7 Adjust the phase Angle until a horizontal, right-to-left lift-off signal is achieved.
8 Position the probe in the hole, verify the coil is 90° away from the EDM notch and Null the instrument.
9 Rotate the probe in the hole to detect the 0.020 inch notch.
10 Adjust the phase Angle to obtain a vertical signal from the EDM notch.
11 Adjust the Vertical and Horizontal Gain to achieve an 80% FSH vertical deflection peak to peak for
differential/reflection, or 50% FSH vertical deflection for absolute probes from the 0.020 EDM notch (Ref.
Figures 210 and 211).
Table 206. Initial Instrument Settings for Olympus Nortec 500D Bolt Hole Inspection of Aluminum
using a Differential/Reflection Probe
CONT Cont Null OFF
SWEEP Sweep OFF
Probe Drive High

20-00-00 (Rev D3)

Table 207. Initial Instrument Settings for Olympus Nortec 500D Manual Bolt Hole Inspection of
Aluminum using an Absolute/Bridge Probe
CONT Cont Null OFF
SWEEP Sweep OFF
Probe Drive Mid
(b) Manual Fastener Hole Inspection Procedures
CAUTION: Visually verify the hole surface condition will not damage the probe during inspection and is
void of foreign material such as metal shavings, sealant, grease or other debris.
NOTE: The scan speed (rotation of probe) shall be the same speed which is used for standardization.
Indexing shall be 1/2 coil diameter maximum between each scan.
Re-nulling may be required on the component being inspected due to minor variations
between the component and the material composition of the standard.
1
Insert the probe into the appropriate hole of the part to be inspected. Ensure good contact between the probe's
coil and the inside surface of the hole.
2 Position the probe's coil immediately within the upper or lower edge of the hole so that the center line of the coil
is even with the surface of the part. Scan the entire diameter of the hole turning the probe 360°. Scan index shall
be no greater than 0.060 inch.
3 Scan the entire length of the fastener hole twice. A probe collar type fixture shall be utilized to ensure proper
indexing for complete coverage through the length of the hole.
(c) Indication Evaluation
1 Any Vertical deflection that is distinguishable (separated) from the background noise and not caused by lift-off or
part geometry shall warrant further examination and rescanning of the area of interest.
2 Mark any repeatable vertical deflection crack-like indications equal or greater than 25% FSH (for absolute probe
calibrations) or 40% PTP FSH (for differential/reflection probe calibrations) above the baseline/null point. Any
repeatable crack-like indications equal or greater than 25% FSH (for absolute probe calibrations) or 40% PTP
FSH (for differential/reflection probe calibrations) above the baseline/null point not caused by lift-off or part
geometry shall be considered a crack and reported via the reporting instructions.
(d) Acceptance and Rejection Criteria
1 No cracks allowed. If ANY evidence of cracks or other discrepancies are found, such as small cracks starting
from rivet holes; hairline cracks in the spar caps, sheared or deformed rivets, contact Textron Aviation Technical
Support for consultation.
(8) Automated Scanner Fastener Hole Inspection
NOTE: Standardization should be verified at least every 30 minutes. If the original sensitivity requirements
are not met following any standardization verification, all inspections accomplished since the last
validated standardization must be re-accomplished.

20-00-00 (Rev D3)
The part to be inspected, calibrated standard, inspection unit, and probe must be at ambient
temperature to assure that valid test data is obtained.
(a) Automated Scanner Fastener Hole Standardization (Calibration)
NOTE: Standardization of the Eddy Current equipment will vary depending on the manufacturer. Use
of the manufacturer's Operation Manual is recommended. The inspection personnel should be
familiar with the equipment and it's operation and limitations.
The following instrument settings are meant as a guide, for automated fastener hole probe inspection. Minor
adjustments may be necessary to optimize the setup; However, the sensitivity level shall be achieved.
1 Connect the appropriate diameter of probe for the hole to be inspected to the scanner.
2 Connect the cable and scanner to the instrument, and turn the instrument ON.
CAUTION: High pass and Low pass filters used with automated fastener hole scanners shall be
appropriate for the hole/probe diameter and the RPM of the automated scanner probe/coil.
Improper filter settings for a given RPM of the probe/coil can suppress relevant crack
responses.
NOTE: Apply Teflon tape (18, Table 210, 91-00-00) to the probe as required to prevent wear,
reduce drag and signal noise caused by scanning rough surfaces. Always confirm
standardization sensitivity when Teflon tape is replaced.
3 Adjust the initial settings to those provided in Table 208.
4 Adjust the filters as recommended per the manufacturer's operation manual.
5 With the scanner turned OFF, insert the probe into the appropriate size hole in the calibration standard for the
hole diameter to be inspected. Position the probe away from the edge of the hole and 90° from the EDM notch.
A snug fit in the hole without binding is required. While holding the probe still, null the instrument. The instrument
should null at the 50% vertical and horizontal positions. If not, adjust the vertical and horizontal positions to 50%
and Null the instrument.
6 Remove the probe from the hole.
7 Ensure the sweep mode of the instrument is OFF, and hold the scanner so that the probe is parallel to the
reference standard. Place the probe in contact with the flat surface of the reference standard at least 0.25 inch
away from any edges or EDM notches. Turn the scanner on to generate a lift-off signal.
8 Adjust the phase angle to achieve a horizontal lift-off signal.
9 Ensure the sweep mode of the instrument is off. Turn the scanner on and reinsert the probe into the appropriate
hole in the calibration standard.
10 Adjust the Vertical Gain and Horizontal Gain independently to place the notch response on the screen at a 45°
angle (1:1 Slope) extending with an 80% FSH and 80% FSW PTP signal (Ref. Figure 212 and Figure 215).
11 Turn the external sweep on(Ref. Figure 216).
12 With the scanner turned off, insert the appropriate size hole in the reference standard 90° away from the EDM
notch and edges of the hole and press NULL.
13 Remove the probe from the hole.
14 Turn the scanner on and insert the probe back into the appropriate hole in the reference standard. Maximize the
signal from the 0.020 inch EDM notch. If the required 80% PTP response is not achieved, adjust the horizontal
and vertical gains simultaneously until the 80% PTP response is achieved (Ref. Figure 213 and Figure 214).
NOTE: Noise in excess of 20% PTP during operation of the scanner while performing calibration
of the inspection system will require correction by replacing the item, causing the
excessive noise, i.e. the probe, cable or scanner.
Table 208. Initial Instrument Settings for the Olympus Nortec 500D Automated Scanner Bolt Hole
Inspection of Aluminum or Ferromagnetic Steel Using a Differential/Reflection Probe

20-00-00 (Rev D3)

CONT Cont Null OFF
SWEEP Sweep HIGH
Probe Drive Mid
Scanner RPM 1200
(b) Automated Fastener Hole Inspection Procedures
CAUTION: Visually verify the hole surface condition will not damage the probe during inspection and is
void of foreign material such as metal shavings, grease, sealant, or other debris.
1 With the scanner turned OFF, insert the probe into the hole and check for proper fit comparable to fit in the
appropriate hole in the reference standard. Hold the probe steady and Null the instrument.
2 Turn the scanner on and insert the probe into the hole. For manual feed type scanners, slowly push the probe
through the entire length of the hole and slowly pull the probe back through the hole. Ensure complete coverage
of the entire length of the hole for the rotation and feed speed used. The scan speed (rotation of the probe) shall
be the same speed which was used for standardization. For translate/rotate type scanners, the travel shall be
adjusted to index no more than 1/2 of the coil diameter. Scanning shall be performed a minimum of twice for
each hole to be inspected.
(c) Indication Evaluation
1 Any vertical deflection that is distinguishable (separated) from the background noise and not caused by lift-off or
part geometry shall warrant further examination and rescanning of the area of interest.
2 Bolt holes which exhibit noise equal to or greater than 20% FSH PTP shall be flex honed or reamed and
reinspected. Contact Textron Avaition Technical Support prior to reaming any holes.
3 Mark all repeatable crack-like indications equal to or greater than 30% vertical deflections above the
baseline/null point. Any repeatable crack-like indication equal to or greater than 30% FSH above the
baseline/null point shall be marked and reported via the reporting instructions.
(d) Acceptance and Rejection Criteria
1 No cracks allowed. If any evidence of cracks or other discrepancies are found, such as small cracks starting
from rivet holes; hairline cracks in the spar caps, sheared or deformed rivets, contact Textron Aviation Technical
Support for consultation.

20-00-00 (Rev D3)
Figure 201 : Sheet 1 : Maximum Probe Diameter

20-00-00 (Rev D3)
Figure 202 : Sheet 1 : Response from 0.010, and 0.020 inch Deep Notches with Acceptable Signal-to-Ration

20-00-00 (Rev D3)
Figure 203 : Sheet 1 : Response from a 0.020 inch Deep EDM Notch

20-00-00 (Rev D3)
Figure 204 : Sheet 1 : Lift-off Compensation for Paint Thickness

20-00-00 (Rev D3)
Figure 205 : Sheet 1 : General Surface Scanning Directions

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Figure 206 : Sheet 1 : Scanning Around Flush Fasteners

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Figure 207 : Sheet 1 : Scanning Around Protruding Fasteners

20-00-00 (Rev D3)
Figure 208 : Sheet 1 : Scanning of Radii

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Figure 209 : Sheet 1 : Scanning Direction of Aft Spar Lower Spar Cap Surfaces

20-00-00 (Rev D3)
Figure 210 : Sheet 1 : Inspection Areas Bathtub Fittings

20-00-00 (Rev D3)
Figure 211 : Sheet 1 : Inspection Areas Counterbore Radius

20-00-00 (Rev D3)
Figure 212 : Sheet 1 : Lower Forward Fitting Inspection

20-00-00 (Rev D3)
Figure 213 : Sheet 1 : Inspection Areas Gen III Fittings

20-00-00 (Rev D3)
Figure 214 : Sheet 1 : 80% Full Screen Height Calibrated Signal Response From 0.020 Inch Notch, Manual Bolt Hole
Differential/Reflection Probe

20-00-00 (Rev D3)
Figure 215 : Sheet 1 : 80% FSH and 80% FSW at a 45° (1:1 Slope) Impedance Plane Display

20-00-00 (Rev D3)
Figure 216 : Sheet 1 : 80% Full Screen Height Calibrated Signal Response From 0.020 Inch Notch, External Sweep Probe Automated
Bolt Hole


Standard Practices Airframe 1. Fluorescent Liquid Penetrant Inspection

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Structural Inspection and Repair Manual (Rev D3)

20-00-00 (Rev D3)

STANDARD PRACTICES AIRFRAME

Copyright © Textron Aviation Inc. Page 1 of 29

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3/4 Inch 3 3/4 Inch 6300

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Eddy current sliding probe 1kHz- SPO3806 1kHz - 10kHz/ order

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8 If required, perform Steps 3. thru 6. with the appropriate shims in place.

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the maintenance manual.

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V-POS Vertical Position 50

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ANGLE Angle (Phase) 22 degree

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Figure 201 : Sheet 1 : Maximum Probe Diameter

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Figure 204 : Sheet 1 : Lift-off Compensation for Paint Thickness

Copyright © Textron Aviation Inc. Page 17 of 29

Figure 205 : Sheet 1 : General Surface Scanning Directions

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Figure 206 : Sheet 1 : Scanning Around Flush Fasteners

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Figure 207 : Sheet 1 : Scanning Around Protruding Fasteners

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Figure 208 : Sheet 1 : Scanning of Radii

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Figure 210 : Sheet 1 : Inspection Areas Bathtub Fittings

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Figure 211 : Sheet 1 : Inspection Areas Counterbore Radius

Copyright © Textron Aviation Inc. Page 24 of 29

Figure 212 : Sheet 1 : Lower Forward Fitting Inspection

Copyright © Textron Aviation Inc. Page 25 of 29

Figure 213 : Sheet 1 : Inspection Areas Gen III Fittings

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