LEARJET 40 SERIES

NONDESTRUCTIVE INSPECTION MANUAL

FUSELAGE SKIN THICKNESS

1. Purpose

A. This procedure is to measure the skin thickness at different locations on the fuselage.

2. General

A. The areas in this procedure for each model are given at the intersections of frames and stringers. You
must measure the skin thickness adjacent to this intersection. Do not measure the skin thickness over
the frame or stringer. The probe must be located on a firmly supported, single skin ply, and away from
any conductive material which may be in contact with the inner skin surface.

B. This inspection procedure shall be performed by qualified personnel in accordance with the General
Section (Part 6) of this manual.

PART NAME PART NUMBER ZONE MATERIAL

Skin Panel Lower Flight 4553206000 220 2024T3
Deck
Canopy Skin 4553306002 220 2020T3
L/H Upper Fuselage 4553306005 230 2024T3
Skin 45 Model
R/H Upper Fuselage 4553306006 230 2024T3
Skin 45 Model
L/H Lower Fuselage 4553306000 230 2024T3
Skin 45 Model
R/H Lower Fuselage 4553306001 230 2024T3
Skin 45 Model
L/H Upper Fuselage 4553326001 230 2024T3
Skin 40 Model
R/H Upper Fuselage 4553326002 230 2024T3
Skin 40 Model
L/H Lower Fuselage 4553326003 230 2024T3
Skin 40 Model
R/H Lower Fuselage 4553326004 230 2024T3
Skin 40 Model
Upper Skin Panel Top 4553406000 230 2024T3

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3. Equipment and Materials

A. The following inspection equipment and materials may be used for the completion of this procedure.

NOTE: You can use equivalent alternatives for these items:

NAME PART NUMBER MANUFACTURER USE

Eddy Current Instrument Nortec 2000 Staveley NDT Flaw Detection.
Technologies,
Kennewick, WA
Calibration Standard 23-55ST Learjet, Inc. Eddy Current System
28%-35% I.A.C.S. AL Wichita, KS Calibration.
Calibration Standard 12045-009 NDT Engineering Corp. Eddy Current System
28%-35% I.A.C.S. AL a company of Olympus Calibration.
NDT, Kent, WA
Eddy Current Probe, L8503-5 NDT Engineering Corp. Flaw Detection.
0.3 inch dia. probe tip, a company of Olympus
1-15 kHz NDT, Kent, WA
Cable C2BN-2M-6 NDT Engineering Corp. Flaw Detection.
a company of Olympus
NDT, Kent, WA
White Cotton Wiping Commercially available Clean inspection area.
Cloths

4. Preparation and Cleaning

A. Wipe inspection areas with a clean cloth to remove any dirt or grease. (See Figure 6-1.)

5. Calibration Procedure

A. Connect the eddy current probe to the eddy current instrument using the manufacturer’s recom-
mended cable.

B. Set the power to on.

NOTE: The eddy current instrument may need to warm up to operating temperature.

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Skin Thickness - Locations Learjet 40

Figure 6-1 (Sheet 1 of 2)

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Skin Thickness - Locations Learjet 45

Figure 6-1 (Sheet 2 of 2)

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C. Set the instrument controls to the values in the following table.

NOTE: Instrument settings in the table below are to be used as a reference. Each manufacturer’s
instrument and probe combination will have different phase and gain settings for optimum
operation and sensitivity.

INSTRUMENT SETTINGS
Instrument: Staveley Instruments Model No. Nortec 2000
Frequency 5.5 kHz
Phase 42
Gain Vertical 82
Gain Horizontal 70
Probe Drive MID
Low Pass Filter 100 Hz
High Pass Filter 0 Hz

D. Select the calibration standard thickness above and below the skin thickness being measured.

NOTE: The nominal thickness of the fuselage skin in all locations is 0.040 to 0.050 inch [1.016 to
1.27 mm].

E. Position the probe in the center of the selected calibration standard step and adjust the indicating dot
to the center of the screen.

F. Adjust the phase angle and horizontal gain so that when you slowly lift the probe from the calibration
standard a straight horizontal lift-off line extends to the left edge of the screen. (See Figure 6-2.)

NOTE: If the aircraft is painted, the paint/body filler thickness must be known. This is determined
by the non-conductive coating thickness check. (Refer to Part 6, 51-00-02.)

G. Create three new lift-off lines on the CRT. (See Figure 6-3.)
(1) For a skin thickness of 0.040 inch [1.016 mm] do the steps that follow:
(a) The center line represents the 0.040 inch [1.016 mm] calibration standard step and paint com-
pensation shim.
(b) The upper line represents the 0.038 inch [0.9652 mm] calibration standard step and paint
compensation shim.
(c) The lower line represents the 0.042 inch [1.0668 mm] calibration standard step and paint com-
pensation shim.
(2) For a skin thickness of 0.050 inch [1.27 mm] do the steps that follow:
(a) The center line represents the 0.050 inch [1.27 mm] calibration standard step and paint com-
pensation shim.

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(b) The upper line represents the 0.048 inch [1.2192 mm] calibration standard step and paint
compensation shim.
(c) The lower line represents the 0.052 inch [1.3208 mm] calibration standard step and paint com-
pensation shim.
(3) Adjust the instrument until the upper and lower lift-off lines go over the adjacent grid lines above
and below the center line. (See Figure 6-3.)

Center Line
Figure 6-2

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Upper and Lower Limits - Skin Thickness

Figure 6-3

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6. Inspection Procedure

A. With the three reference lines on the screen, put the probe on the skin at one of the locations shown in
Figure 6-1.

B. When you remove the probe a new skin thickness lift-off line is shown on the instrument CRT display.

C. Estimate the skin thickness from the position of the skin lift-off line relative to the three calibrated lift-off
lines. (See Figure 6-4.)

NOTE: The skin thickness for the example in Figure 6-4 is: greater than 0.038 inch [0.9652 mm],
but less than 0.040 inch [1.016 mm]. Record as 0.039 inch [0.99063 mm].

D. If the skin lift-off line is outside the upper or lower reference lines, repeat steps 6.A. through 6.C. Use
the calibration standard step closest to the estimated skin thickness. Repeat this procedure until the
skin lift-off line is between the upper and lower calibrated lines.

E. Do steps 6.A. through 6.D. for each of the locations shown in Figure 6-1.

NOTE: The calibration of the instrument MUST be verified before and after each measurement.

7. Acceptance/Rejection Criteria

A. For a skin thickness of 0.040 [1.016 mm], 0.0370 [0.9398 mm] is the minimum allowable skin thick-
ness.

B. For a skin thickness of 0.050 [1.27 mm], 0.0460 [1.1684 mm] is the minimum allowable skin thickness.

NOTE: If the thickness is under the minimum value, contact Field Support Engineering for disposi-
tion.

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Skin Lift-Off Line

Figure 6-4

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