INTRODUCTION. What does this mean for Engineering? Specifically, what does it mean for NDT?

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Lindsey Hardy
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1 B787 READINESS 1

INTRODUCTION This week marks the introduc=on of the B787-9 to the QANTAS fleet There is great excitement and expecta=on within our organisa=on for the aircraf and

2 INTRODUCTION This week marks the introduc=on of the B787-9 to the QANTAS fleet There is great excitement and expecta=on within our organisa=on for the aircraf and its poten=al to deliver improved comfort, performance and safety for the customer. What does this mean for Engineering? Specifically, what does it mean for NDT? 2

3 The Journey In January 2003, Boeing announced the B787 as the replacement product for its cancelled Sonic Cruiser program. This was driven by the airlines shif is opera=on strategy from hub and spoke routes to point to point routes. AFer numerous produc=on and flight test delays, the first aircraf was delivered to ANA in September 2011 The B787-8 entered service with Jetstar in October

4 What is a B787? The Boeing 787 uses more composite materials in its airframe and primary structure than any previous Boeing commercial airplane. Approximately 53% Because of the extensive use of composites, it is important to understand terms and concepts about composite materials. In addi=on to more composite materials, the geometry of the 787 structure is different from previous Boeing models. It is also important to understand the differences between damage evalua=on for metallic structures compared to damage evalua=on of composite structure. 4

5 Material ApplicaAons 5

6 Material SpecificaAon 6

7 Challenges In the world of Specialist Maintenance, NDT inspectors are authorised to perform a process. There is no type ra=ng for NDT inspectors. In fact, your NDT inspector is already authorised to perform that process on the aircraf that hasn t been built yet! However, in the Part145 MOS, the AMO is required to ensure that a cer=fying employee has an adequate understanding of the aircraf or aeronau=cal product. 7

8 What do we need to do for our inspectors? 1) Safety. 2) Structural awareness. 3) Documenta=on. 4) Applica=ons. 8

9 Safety We needed to generate a safety awareness training package for anyone working on the aircraf. The B787 uses many new electro-mechanical systems not seen on previous fleets. Employee s need to recognise dangers and be alert to poten=al hazards. 9

Structural Awareness Qantas developed a structural awareness training package for all employees in contact with the aircraf. The NDT inspector also needs to competently navigate the SRM.

10 Structural Awareness Qantas developed a structural awareness training package for all employees in contact with the aircraf. The NDT inspector also needs to competently navigate the SRM. Not all B787 s are constructed the same. There are significant differences between the B787-8 and B Each have there own SRM. The inspector needs to be aware of the manufacturing terms and techniques of the materials used. 10

11 Structural Awareness From the rela=vely simple structures 11

12 Structural Awareness To the more complex 12

13 Structural Awareness Add Stringers 13

14 Structural Awareness And frames 14

15 DocumentaAon The SRM (and AMM) use new Data Module Code (DMC) for S1000D delivery into Maintenance Performance Toolbox. Delivery of S1000D data into Toolbox uses a Standard Numbering System (SNS) applying a Data Module Codes (DMC's) to each SRM Procedure. Each DMC has mul=ple Disassembly Codes within an ATA (beginning at 00A and con=nuing with 01A, 02A, 03A and so on) along with an Info Code that iden=fies the type of SRM Data. 15

16 ApplicaAons Boeing produce for the Airlines, a tooling and equipment master list for Entry into Service The only NDT tool listed in the master list is the GEnx Fan Blade Ultrasonic Inspec=on Kit for post bird strike fan blade inspec=on 16

17 ApplicaAons Airplane hit by ground equipment Fuselage Bird Strike Fuselage Lightning Strike Fan Blade Lightning strike Fan Blade Leading Edge repair Fuselage Bonded repair Inspec=on Wing Lower surface post tyre shred B787-9 Horizontal and Ver=cal Stabiliser Leading Edge skins for s=ffener disbond B787-8 Horizontal Stabiliser Leading Edge for skin to core delamina=on B787-9 Horizontal Stabiliser leading edge Hybrid Laminar Flow Control (HLFC) for skin to core delamina=on Ver=cal Stabiliser leading edge skin to core delamina=on Wing Leading edge heated and unheated slats 17

18 ApplicaAons Damage detec=on in BMS8-276 material Boeing NDT manual allows two methods: Guided A scan at 4mm increments TCG Time consuming No post inspec=on analysis 18

19 ApplicaAons Recommended is the Ultrasonic Linear array (PAUT) with a two dimensional encoder system 19

20 ApplicaAons Bonded Repair Inspec=on C scan method is recommended where access and surface condi=ons are sa=sfactory. Provides significant post inspec=on analysis 20

21 ApplicaAons Bondline flaws 21

22 ApplicaAons Porosity Calcula=ons 22

23 ApplicaAons B787-9 Horizontal Stabiliser Leading Edge skin (Hybrid) Laminar Flow Control (HFLC) Employs a nominated Bond tester (resonance mode) 23

24 ApplicaAons Ver=cal Stabiliser Leading edge skin to core Employs a Bondtester in the pitch/catch mode but is only applicable if the Aluminium erosion shield is bonded to the GRFP 24

25 ApplicaAons GEnx Fan Blade Inspec=on post Bird Strike 25

26 ApplicaAons Ramp Damage Checker The procedure to use the RDC is contained in the SRM (not the NDT manual) There are limita=ons where the RDC is used Only laminated structures 26

27 ApplicaAons Ramp Damage Checker This is a basic Ultrasonic Instrument calibrated on the aircraf structure. It displays Good or Bad and will need to be recalibrated for each thickness to be inspected It is designed to be used by Non NDT people, however, indica=ons should be verified by instrumented NDT methods 27

Resources The sophis=ca=on of the aircraf compared to metal types, and poten=al route opportuni=es also presents challenges on where to posi=on resources.

28 Resources The sophis=ca=on of the aircraf compared to metal types, and poten=al route opportuni=es also presents challenges on where to posi=on resources. The high cost of ini=al equipment set up, and inspector familiarisa=on/ training is prohibi=ve in a small fleet. Consolida=on, resource pooling and recogni=on of other MRO s (outside the Australian regula=ons) to support the fleet must all be considered. 28

29 Summary To ensure adequate understanding we need to consider, train and document 1) Safety. 2) Structural awareness. 3) Documenta=on. 4) Applica=ons. 29

30 Acknowledgements Boeing 787 Structural Awareness training package Australian Avia=on magazine Boeing 787 NDT manual Boeing B787-9 SRM The Australian Business Traveller 30

31 31

E-Enabled Vision & Strategy

E-Enabled Vision & Strategy AIA /ATA/ ASD S1000D Users Forum October 12- October 15, 2009 Crown Plaza Hilton Head Resort, Hilton Head, SC, USA S1000D for Boeing 787 Freelon F. Hunter The Boeing Company