Model 525A/525B Nondestructive Testing Manual (Rev 16)

53-30-03 (Rev 16)

FUSELAGE SKIN JOINT (EDDY CURRENT) SPECIAL DETAILED INSPECTION

1. Description.
A. Examine the fuselage skin joints of Model 525A or 525B aircraft for cracks resulting from fatigue or damage from earlier
cleanout operations. The calibration and inspection procedure is the same for the 525A and the 525B with the exception of the
location of the skin joints on the aircraft. For the location of the fuselage pressure vessel skin joints refer to Figure 201 for the
Model 525A and Figure 202 for the Model 525B.
NOTE: Only the production/blueprint skin splice joints are shown in the figures. Skin joints created as a result
of field activity, (for example, structural repair, alteration or modification) must also be identified and
inspected. Applicability and (if required) adjustment of the standard inspection procedure to non-
production installation(s) must be determined prior to examination.
B. This procedure is only required to be performed on exposed skin joints. Examination under fairings, pylons, or other panels or
structure is not required.
C. It is optional to use procedure Part 6, 53-30-04, Fuselage Skin Joint (Magneto-Optics) Special Detailed Inspection.
D. This inspection satisfies the requirements of the maintenance manual inspection program as indicated below. Refer to Table
201.
Table 201. Inspections
AIRPLANE TASK NUMBER
MODEL 525A 53-00-01-250
MODEL 525B 53-00-01-250
2. Preparation.
A. Prepare the airplane.
(1) Clean the area to be examined of any unwanted material that would interfere with the inspection. Take care to wipe down
the exterior of the aircraft along the skin joints to help prevent scratches in the finish due to dust, dirt, or other gritty material
being on the aircraft.
3. Equipment.
A. The equipment used in the development of this procedure is listed in Table 202.
NOTE: Equivalent eddy current equipment may be used provided it meets the sensitivity requirements of this
procedure.
NOTE: This procedure requires the use of an eddy current instrument with an impedance plane display. No
substitutes are allowed.
NOTE: No substitution of the inspection kit is allowed unless specified in Part 6, 20-10-00, Cross Reference
Table.
Table 202. Equipment List
NAME NUMBER MANUFACTURER
Eddy Current Instrument US-454 EddyView UniWest
122 South 4th Avenue
Pasco, WA 99301
Phone: (1) 509-544-0720
Fax: (1) 509-544-0868
Web: http://www.uniwest.com/index.html
Eddy Current Instrument NDT 19eII Olympus NDT
48 Woerd Avenue
Waltham, MA 02453
Phone: (1) 781-419-3900
Fax: (1) 781-419-3980
Web: http://www.olympusndt.com/en/

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Reference Standard Kit 6383103 Textron Aviation

(Note 1) Technical Manual Distribution Center
2121 S. Hoover Road Building C10
Wichita, KS 67209
Phone: 316-517-6215
Email: TMDC@txtav.com
Web: ww2.txtav.com/TechnicalPublications
NOTE 1:
Refer to Cross Reference Table Part 6, 20-10-00 for a description of this kit and its contents.
4. Calibration.
NOTE: The skin butt joint and lap joint calibration procedures are essentially the same. Any differences will be
noted when required.
A. Calibrate the Instrument.
(1) Connect the probe to the instrument.
(2) Set the instrument frequency to 7.6 kHz.
(3) Set the probe drive to MID.
(4) Set the low pass filter to 100 Hz.
(5) Set the instrument gain to an initial setting of approximately 50 dB vertical and 50 dB horizontal.
(a) If your instrument adjusts the gain differential with volts/division, adjust the X and Y volts/division to be equal and an
initial gain setting of 45 dB.
(6) Put the probe in the null position on the butt joint, or lap joint splice of the reference standard. Refer to Figure 205.
NOTE: The sliding probe will rest at a slight angle on a skin lap joint.
NOTE: Sliding probes are directionally sensitive and must be oriented as indicated.
(7) Push the null button.
(8) Position the null point on the instrument display at approximately the 20% vertical and 70% horizontal screen position.
(9) Monitor the display as you lift the probe from the standard.
(10) Adjust the instrument phase so that the response from liftoff moves down and to the right, from the null point. Refer to
Figure 206 for butt joint or Figure 207 for Lap Joint.
(11) From the null position on the reference standard, slide the probe along the joint, towards and over the EDM notch. Refer to
Figure 205 for the location of EDM Notches.
(12) The response from the EDM notch should travel up and to the left from the null position.
(13) Adjust the instrument gain so the spread in the signal from the null point to the peak from the EDM notch is 6 major
divisions. Refer to Figure 206 for butt joint or Figure 207 for Lap Joint.
NOTE: This sets the scan sensitivity level or scan reference level. This is not a reject level. There are no
acceptable cracks. Any confirmed crack, regardless of signal amplitude, shall be rejected.
5. Inspection.
A. Inspect the fuselage skin joints.
(1) Calibrate the equipment.
(2) Put the probe on the appropriate skin joint on the fuselage.
NOTE: Make sure that the probe is centered on and in line with the skin joint.
(3) Push the null button.
(4) Slide the probe along the skin joint at a scan speed of approximately 1.0 to 2.0 inches (25.4 to 50.8 mm) per second.
(a) Keep the probe centered on the joint, movement off of the joint will cause the signal to move down to the right and off
screen.
(5) Examine the entire length of each skin joint in the pressure vessel. Refer to Figure 201 for the Model 525A and Figure 202
for the Model 525B.
(a) If necessary, attach a straight edge as a guide to keep the probe centered over the skin joint.

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

B. If the skin joints are not easily located visually due to paint or aerodynamic filler obscuring the joint. Do the steps that follow to
locate and mark the joint so it can be examined.
NOTE: This is only necessary on butt joints, it will not be necessary on lap joints.
(1) Put the sliding probe on the reference standard as shown in Figure 205.
(a) Positioning the probe over fasteners common to the joint will have no effect on the signal for this process.
(2) Use all of the same equipment settings from the calibration steps above.
(3) Push the null button.
(4) Slide the probe across the joint at a right angle to the joint and monitor the display. Refer to Figure 205.
(5) When the joint is crossed, the signal will move up and to the left, very similar to the indication from the EDM notch.
(6) When the signal peaks, the centerline of the probe will be directly over the center of the joint. Refer to Figure 208.
(7) On the aircraft, put the probe in the approximate area of the skin joint with the probe center line parallel to the suspected
direction of the skin joint.
(8) Push the null button.
(9) Slide the probe across the skin joint at a right angle to the suspected orientation of where you believe the skin joint to be.
NOTE: Be careful that you do not put the probe too far from the joint for your starting point. The edges
from any underlying structure, i.e. stringers, doublers, etc... will have an effect on the signal. Refer
to Figure 208.
(10) Use a grease pencil or other suitable marker to mark the location of the joint for the entire length that is obscured.
C. If the above procedure does not produce satisfactory results. Set up for a surface eddy current inspection and scan across
where the joint should be. The edge of the skin will give a response similar to a crack.
D. Any vertical deflection of the eddy current signal traveling in the same orientation as a crack must be evaluated to determine if a
crack exists. Do the steps below to help determine if the indication is a crack.
(1) Remove all paint sealer and/or aerodynamic filler from the joint for approximately 3.0 inches (76.2 mm) in each direction
from the crack indication. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish -
Cleaning/Painting.
(2) Visually examine the area looking for evidence of cracks or damage.
(3) Re examine the area of the crack indication with the sliding probe.
(4) If the crack indication is gone, it was caused from some contaminate in the paint, sealer or filler.
(a) Restore finish in the area where the finish was removed.
E. If the existence of a crack is confirmed, you must do the following:
(1) Do the optical micrometer procedure as defined in Part 9, 53-30-03, Optical Inspection Of Skin Joints.
(2) Do this eddy current inspection on the tailcone skin joints. The calibration and inspection procedure is the same as for the
pressure vessel. For the location of production skin joints on the tailcone refer toFigure 203 for the Model 525A and Figure
204 for the Model 525B.
(3) If a crack is found and confirmed on a tailcone joint, that joint must also be inspected with the optical micrometer procedure
as defined in Part 9, 53-30-03, Optical Inspection Of Skin Joints.
6. Part Disposition.
A. If a crack is found, report this information to Textron Aviation. Refer to Introduction for Team Structures website information to
complete the Structural Damage Report and Service Request (SDR). Make sure to provide the following information:
(1) Crack Location.
(2) Crack length.
(3) Crack Orientation.
(4) Photographs (E-mail or fax) if possible of defect area, screen captures, etc.

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 201 : Sheet 1 : 525A Skin Joints

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 202 : Sheet 1 : 525B Skin Joints

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 203 : Sheet 1 : 525A Empennage Joints

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 204 : Sheet 1 : 525B Empennage Joints

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 205 : Sheet 1 : EDM Notch Reference Standard

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
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Figure 206 : Sheet 1 : Butt Joint Signal Response

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
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Figure 207 : Sheet 1 : Lap Joint Signal Response

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 Model 525A/525B Nondestructive Testing Manual (Rev 16)
53-30-03 (Rev 16)

Figure 208 : Sheet 1 : Skin Joint Signal Response

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