penetrant inspection1

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SPECIFICATION NDTS 1101REVISION: HDATED : July 3, 1991SUPERSEDES: NDTS 1101GDATED: Mav 21, 1990(Inc. Am. 2 & 3)

P E N E T R A N T I NS PE CT I O N

CONTRACT NO. F33657-84-C-0247

This document contains Technical Data considered tobe a resource under l-402b.3 of DoD Regulation Number5400.7-R and is not a “record” required to be releasedunder the Freedom of Information Act.

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GENERAL DYNAMICSFORT WORTH DIVISIONCODE IDENTIFICATION 81755

SPECIFICATIi3N NDTS 1101REVISION: HDATED: July 3, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990

P E N E T R A N T I NS PE CT I ON

PREPARED BY:

IL& &QA E@ineerNondestructive EngineeringDevelopment ,Dated:+ -

APPROVED BY:

NondestructiveEngineering Development &NDT Com$site Inspection

‘ate:* ●

Qual!fty Co>t 01‘a’e:4°hmk&w-Chief, Metallic Materialsand Processes EngineeringDate: ?5W [({q(

,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...>-’. . . . . . . . . . . . . . .

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GENERAL DYNAMICSFORT WORTH DIVISIONCode Identification 81755

SPECIFICATION NDTS 1101REVISION: HDATED: July 3, 1991SUPERSEDES: NDTS 11OIGDATED: May 21, 1990PAGE: i

REVISION H CHANGE INDEX

This document has been completely rewritten in standardspecification format. Due to the extensiveness of change, achange index will not be provided.

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SPECIFICATION NDTS 1101REVISION: HDATED: July 3, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990PAGE: ii

TABLE OF CONTENTS

Paraqra~h *

1.02.03.03.13.23.33.43.54.04.14.24.34.44.54.64.75.05.15.2.5.35.46.07.07.17.27.38.09.010.0

APPENDIX ‘tAn

APPENDIX “BJi

Title

SCOPESPECIFICATIONSREQUIREMENTSPersonnelFacilitiesEquipmentMaterialsInspection SequencePRE-INSPECTION PART PREPARATIONGeneralPreparation of AluminumPreparation of SteelPreparation of TitaniumPreparation of Nickel Based AlloysAlternate Process ApprovalCleanliness Prior To Penetrant InspectionINSPECTION PROCEDUREPenetrant Application and DwellPenetrant RemovalDryingApplication of DeveloperINSPECTIONACCEPT-REJECT CRITERIAIndicationsDiscontinuityZone StandardsPOST-INSPECTION REQUIREMENTSQUALITY ASSUWUfCE PROVISIONSDEFINITIONS

PRODUCTION PENETFUWT DEMONSTRATIONPROGRAM “ZONE 1A, lB, IC” CWiCKDETECTION CAPABILITY

TEST FREQUENCIES

E!a9s?

1233345666791011121515151617171819191920212227

Al

B1

.

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GENE~L DYNAMICSFORT WORTH DIVISIONCode Identification 81755

1.0

1.1

1.2

SPECIFICATION NDTS 1101REVISION: HDATED: July 3, 1991SUPERSEDES: NDTS 11OIGDATED: May 21, 1990PAGE: 1

PENETRANT INSPECTION

SCOPE .

This standard establishes inspection proceduresand process control requirements for liquidpenetrant inspection of metal alloys. Penetrantinspection to this document shall be used whenspecified in Engineering drawings, standards, orspecifications.

For preparation and inspection of materials notcovered in this NDTS, contact GeneralDynamics/Fort Worth Division Process EngineeringDevelopment & Control for specific instructions.Any exceptions to this standard must be approvedby General Dynamics Process EngineeringDevelopment & Control. In special cases,additional inspections may be directed byEngineering and/or Process Engineering Development& Control.

1.3 This standard applies to fluorescent penetrantinspections (FPI) performed on details andassemblies.

.1.4 - Facilities inspecting parts for which ZONE 1A, lB,

and/or lC are specified shall be qualified bysuccessful completion of a Penetrant DemonstrationProgram. (See Appendix “A”) Successfulqualification at a higher zone constitutesqualification at any lesser zones, e.g., ZONE lBqualification covers ZONE 1A.

1.5

1:6

This standard supersedes NDTS 10.00 and shall beused whenever NDTS 10.00 is required. When NDTS10.00 is required, use the accept/reject criteriaper NDTS 1101-1.

This standard shall become effective upon date ofissue.

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2.0

ASTM

SPECIFICATIONS .

SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990PAGE: 2

The following publications shall be applicable tothe extent specified herein or as defined on thecontract or purchase order. Refer to GDFW 16PR711document for the applicable issues of F-16Materials Procurement and ProcessingSpecifications. Insofar as any of thepublications conflict with the requirements ofthis standard, this standard will prevail.

D 95

FPS-1051

FPS-1097

FPS-3008

FPS-3020

FQML-3020

FQPL :NDTS 1101

FZM 1372!3

MIL-A-83444

MIL-I-25135

MIL-L-9909

MIL-STD-41O

MIL-STD-45662

NDTS 10.00

NDTS 1101-1

Test for Water in Petroleum Products andBituminous Materials by Distillation

Chemical Milling of Metals

Inspection and Acceptance Standards forFusion Welds, Specification for

Marking of Aircraft and Aerospace GroundEquipment Parts

Cleaning, Descaling for CRES Steels

Fort Worth Qualified

Fort Worth Qualified( FQPL)

Manufacturer’s List

Processors List

Nonconforming Material Corrective Actionand Disposition Action

Airplane Damage Tolerance Requirements

Inspection Material, Penetrant

Light, Ultraviolet, Metals Examining

Qualification of Inspection Personnel

Calibration Systems Requirements

Penetrant Inspection

Penetrant Inspection of F-ill Parts

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SPECIFICATION NDTS 1101REVISION: HDATED: June 21,1991SUPERSEDES: ND’I’S I1OIGDATED: May 21, 1990PAGE: 3

NDTS 1101-2 Portable FPI

NWR 8090 Naval Weapons Report No. 8090, BinomialReliability Table

P.s. 00.04 Materials and Process Control Tank Data

P.s. 40.01 Chemical Cleaning Methods

P.S. 92.01-1 Certification of Nondestructive Testina

3.0

3.1

3.1.1

3.2

3.2.1

3.2.2

3.2.3

Personnel (GDFW).

REC)UIREMENTS .

Personnel.

Penetrant inspection personnel shall be certifiedin accordance with P.S. 92.01-1 for GDFW and MIL-sTD-41O for suppliers and co-producers. onlyLevel II or Level III personnel shall accept orreject penetrant indications.

Facilities.

Supplier and co-producer facilities must beapproved by General Dynamics/Fort Worth DivisionProcess Engineering Development & Control prior tofurnishing senices controlled by this standard.

Suppliers and co-producers must meet therequirements of this standard. Inspection to anyprocedure other than NDTS 1101 must be approved byProcess Engineering Development & Control.

Approval of facilities for inspecting parts toZone 1A, lB, or lC requirements shall be based onsuccessful completion of a Penetrant DemonstrationProgram. This program is administered by GeneralDynamics/Fort Worth Division Process EngineeringDevelopment & Control to demonstrate penetrantdetection capability on a specific flaw size with90% probability of detection at a confidence levelof 95%. Details of the penetrant demonstrationprogram are shown in Appendix “A”.

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SPECIFICATION NDTS 1101 m

REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990PAGE: 4

3.2.4 Qualified facilities for Zone 1A, lB and lCinspection are listed in FQPL: NDTS 1101.

3.3 EauiDment.

3.3.1 Backlight equipment.

3.3.1.1 Backlight requirements shall be in accordancewith MIL-L-9909.

a)

3.3.2

3.3.3

b)

.

Special application backlights (i.e.,backlight fiber optics, pencil lights,explosion-proof backlights, etc.) shall notbe used unless written approval has beengranted by General Dynamics/Fort WorthDivision Process Engineering Development &Control (GD/FW Pr-oduction Inspection isexcluded from this requirement) . Onlyexplosion-proof backlights may be used onaircraft which contain or have contained fueland present a safety hazard.

The following will be adhered to whenutilizing the explosion-proof backlight:

1) Backlight will be held three inches orless from the surface to be inspected.Should access to the area of interestprohibit this, then the standard 100-wattbacklight will be utilized and the FireDepartment will be called on stand-by.

2) Assure appropriate steps have been takento obtain maximum darkness in area ofinterest.

Backlight meter, Black-Ray Model J-221 orequivalent, shall be used to measure ultravioletlight intensity when required.

White light meter, Weston 703 or equivalent, shallbe used to measure white light intensity whenrequired.

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SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 11OIGDATED: May 21, 1990PAGE: 5

3.4 Materials.

3.4.1 Penetrant materials shall be selected from thecurrent Qualified Products List (QPL) of MIL-I-25135 unless otherwise permitted by GeneralDynamics/Fort Worth Division Process EngineeringDevelopment & Control.

3.4.2 Only Type 1 fluorescent penetrants shall be used.

3.4.3 Each facility approved for Zone 1A, lB and/or lCinspection shall be qualified using specificpenetrant materials which shall not be changedwithout approval of General Dynamics/Fort WorthDivision Process Engineering Development &Control. The facility and the specific materialswill be listed in FQPL: NDTS 1101, latestrevision.

3.4.4 Facilities using materials other than thosequalified for Zone 1A, lB, or lC (i.e. for otherthan Fatigue & Fracture Critical parts) shall meetor exceed the minimum guidelines established inTable 1.

Surface Ins~ected.

TABLE I

MIL-I-25135Sensitivity

Leve 1

All Titanium and High Temperature Alloys 3Machine Surfaces (All Wrought Materials) 3Machined Surfaces (Cast) “3Extruded Surfaces (Except Aluminum & Titanium) 3Forged/Extruded Aluminum 2Cast Surfaces (Except Nickel) 2Forged Surfaces (Except Aluminum,Titanium) 2Nonmagnetic Alloys (Bronze, Brasses, etc.) 2Surfaces Not Covered by Above 2

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GENEW4L DYNAMICSFORT WORTH DIVISIONCode Identification 81755


3.5 Inspection Sequence.

3.5.1 FPI is performed after all fabrication/processingis completed with the following exceptions:

a) FPI before application of any metallic,nonmetallic or organic coating.

b) FPI before shot peening or glass beadblasting.

c) FPI before anodize or them film.

4.0 PRE-INSPECTION PART PREPAWTION.

4.1 General.

4.1.1 For preparation and inspection of materials notcovered in this NDTS, contact GeneralDynamics/Fort Worth Division Process EngineeringDevelopment & Control for specific instructions.

4.1.2 All items to be inspected shall be clean and dryprior to application of penetrant.

4.1.4

4.1.3 If supplier produced parts are etched for reasonsother than pre-penetrant inspection cleaning(e.g., aluminum forgings for grain flow, etc.) andthe required metal removal or more isaccomplished, additional etching per this NDTS isnot necessary provided no subsequent processes areperformed which may smear metal. Refer toParagraph 4.6 for alternate process controls andapprovals.

Machined, ground, vibration deburred, or gritblasted surfaces of aluminum, titanium, corrosionresistant steels, and inconel shall be etchedprior to penetrant inspection unless otherwisespecified by the engineering drawing or ProcessEngineering Development & Control. Etching is notrequired on surfaces which have been wire-brushedby hand or sanded by hand (no power tools).

NOTE : Etching shall not be performed on theairplane or assemblies. Refer to Paragraph 4.1.8.

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SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 11OIGDATED: May 21, 1990PAGE: 7

4.1.5 Areas of parts and holes with tolerances closerthan +/- 0.002$1 and threads must be masked priorto etching. The area masked must be covered towithin ~1/16-inch; i.e., the maskant may extendl/16-inch into the area to be etched or stoppedshort by l/16-inch of the area to be masked.Masking is not required on hole chamfers orcountersinks. Remove plugs and/or maskant priorto penetrant inspection. Drilled holes in non-machined areas of castings/forgings and pilotholes shall not be penetrant inspected unlessspecified on the engineering drawing.

4.1.6 Parts which contain welds, valves, screensfittings, etc., shall not be etched if there is apossibility of etchant entrapment.

4.1.7 Inspection of finished and/or reworked/repairedparts removed from the airplane or stockroom.

a) The finish may be removed by hand-sanding orwith solvent remover. Solvent remover mustbe approved by General Dynamics/Fort WorthDivision Process Engineering Development &Control. Etching is not required prior topenetrant inspection.

4.1.8 Painted parts inspected on assembly or on theairplane:

a) Hand-sanding only (no power tools) shall be“ used to remove paint from aluminum, titaniumor CRES parts unless otherwise permitted byEngineering documentation. Hand-sandingshall be done using 120 grit initially andfinished with 180 grit to eliminate metalsmearing.

b) Clean surface and allow to dry,

4.2 Pre~aration of Aluminum.

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4.2.1 Non-machined aluminum:

a) Vapor or immersion degrease using achlorinated hydrocarbon solvent or inhibitedalkaline cleaner followed by water rinse.Other methods must be approved by ProcessEngineering Development & Control.

4.2.2 Machined, ground, grit blasted, vibration deburredparts and, parts which have been power-sanded,(including castings):

a] Vapor or immersion degrease using achlorinated hydrocarbon solvent or inhibitedalkaline cleaner followed by a water rinse.Other methods must be approved by ProcessEngineering Development & Control.

b) Etch to remove 0.0003 to 0.0007 inch fromeach surface. The etch solution shallproduce a uniformly etched surface withoutpitting or intergranular attack. The”etchprocess shall meet the requirements andprovisions of FPS-1051.

c) The etch solution to be used at GDFW on allaluminum alloys, which may be used bysubcontractors without pre-productionapproval, shall be a room temperaturesolution formulated and maintained as

- follows: 10-22 percent by volumeconcentrated (68%) nitric acid; 3.5-4.5ounce/gallon chromic acid; and 0.55% byvolume concentrated (70%) hydrofluoric acid.Add hydrofluoric acid as required to maintainan etch rate of 0.000015 to 0.000030 inchesper minute per surface on bare 2024-T3 sheetaluminum.

d) Other etch procedures may be used perParagraph 4.6 of this specification.

4.2.3 GD/FW P.S. 40.01-21 describes process proceduresand P.S. 00.04. outlines solution controlparameters.

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4.3 Pre~aration of Steel.

4.3.1 For corrosion resistant steels (excluding 400series) which have been machined, ground,vibration deburred, power-sanded, or grit blasted:


b) Etch to remove 0.0002 to 0.0004 inch fromeach surface. The etched surface shall beuniform with no pitting or intergranularattack. The etch process shall conform toFPS-3020 or FPS-1051.

NOTE: For steels processed per FPS-3020, nofurther passivation is required afterpenetrant inspection, unless subsequentmachining (or other forms of metal removal)is performed. “

c) For corrosion resistant steels (excluding 400series) the etch solution to be used at GDFWand which may be used by subcontractorswithout pre-production approval, shallconsist of a material/process system listedin FQML-3020. Solution controls must be

- compatible with the controls required by theFQML material/process system supplier.

4.3.2 Alternate etch processes for CRES steels may bepermitted with General Dynamics/Fort WorthDivision Process Engineering Development & Controlapproval. Potential processors using alternateetchants shall submit complete process proceduresand controls listed in Paragraph 4.6. Processorsshall make no changes in process solutions,procedures, or solution controls without priorapproval of General Dynamics/Fort Worth DivisionProcess Engineering Development & Control.

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4.3.3 All other steels:a) Vapor or immersion degrease using a

chlorinated hydrocarbon solvent or inhibitedalkaline cleaner followed by water rinse.Other methods must be approved by ProcessEngineering Development & Control.

4.3.4

4.4

4.4.1

4.4.2

GD/’FW P.S. 40.01-24 describes process proceduresand P.S. 00.04 outlines solution controlparameters.

Preparation of Titanium.

Non-machined titanium:

a) Vapor or immersion degrease using achlorinated hydrocarbon solvent and/ordegrease using an inhibited alkaline cleanerfollowed by water rinse. When solventdecreasing is employed, it shall be followedby immersion in inhibited alkaline cleanerand water rinse. Other methods must beapproved by Process Engineering Development &Control.

Titanium parts which have been machined, ground,vibration deburred, power-sanded or grit blasted:

a)

b)

Vapor or immersion degrease using achlorinated hydrocarbon solvent and/or‘degrease using an inhibited alkaline cleanerfollowed by water rinse. When solventdecreasing is employed, it shall be followedby immersion in inhibited alkaline cleanerand water rinse. Other methods must beapproved by Process Engineering Development &Control.

Etch to remove 0.0004 to 0.0008 inch fromeach surface. The etch solution shall producea uniformly etched surface, with no pittingor intergranular attack, and shall introduceno more than 20 ppm hydrogen. The processshall meet FPS-1051 requirements andprovisions.

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NOTE: Unless the pre-approved etch solutionformulation and controls are used,suppliers/coproducers are responsible forperforming the hydrogen content analysisspecified in FPS-1051 on a monthly basis. Thetitanium test specimen shall be processedalong with a batch of GDFW parts.

c) The etch solution to be used at the GeneralDynamics/Fort Worth Division which may beused by subcontractors without pre-productionapproval shall be a room temperature solutionformulated and maintained as follows: 40-50%by volume concentrated (68%) nitric acid and0.5% by volume concentrated (7o%)hydrofluoric acid. Add hydrofluoric acid asrequired to maintain an etch rate of 0.00002to 0.00004 inches per minute per surface onbare 6AL/4V titanium.

d) Alternate etch solutions may be used bysubcontractors subject to the provisions ofParagraph 4.6 of this specification.

4.4.3 GD/FW P.S. 40.01-25 describes process proceduresand P.S. 00.04 outlines solution controlparameters.

4.5 Pre~aration of Nickel Based Alloys

4.5.1 Non~machined nickel based alloys


4.5.2 For MP35N, Inconel 625, and Inconel 718 partswhich have been machined, ground, vibrationdeburred, power sanded or grit blasted.

. . . .. . . . . . . . s mm, ,. ..., ,.

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*GENERAL DYNAMICSFORT WORTH DIVISIONCode Identification 81755


a) Etch to remove 0.0002 to 0.0004 inch fromeach surface. The etch solution shallproduce a uniformly etched surface with nopitting or intergranular attack. The etchprocess shall meet requirements andprovisions of FPS-1051.

b) The etch solution which may be used bysubcontractors without pre-productionapproval shall be a room temperature solutionformulated as follows: 83-89% by volumeconcentrated hydrochloric acid, 1-3% byvolume concentrated nitric acid, 8-16% byvolume deionized water and 175 grams perliter ferric chloride (volume displacementdiscounted). The solution shall maintain anetch rate of 0.000005 to 0.000015 inches perminute per surface on the bare materialundergoing etch.

c) Alternate procedures may be used with GeneralDynamics/Fort Worth Division ProcessEngineering Development & Control approval.Potential processors using alternate etchantsshall submit complete process procedures andcontrols as listed in paragraph 4.6.

4.6 Alternate Process Amroval.

4.6.1 The -use of pre-penetrant etch processes other thanthose specified herein requires pre-productionapproval by General Dynamics/Fort Worth DivisionProcess Engineering Development & Control.Requests for approval shall be accompanied by thefollowing, unless otherwise specified:

4.6.2 For aluminum etch processes:

a) Chemical composition of the proposedsolution(s) .

b) Etch rates, immersion times, and operatingtemperatures of proposed solutions. Etchrates shall be determined for each alloy andheat-treated condition to be processed in thepre-penetrant etch solution.

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c) Solution and etch rate control procedures.

d) The following two (2) coupons furnished byGeneral Dynamics Process EngineeringDevelopment & Control are to be etched at thesame time and then returned to GeneralDynamics/Fort Worth Division ProcessEngineering Development & Control fortesting:

1) A 0.25” x 3“ (approximately) x fullthickness coupon (cut transverse tograin), from 2124-T851 plate over 2“ inthickness, which has been etched in theproposed alternate etchant. The couponwill be examined for uniformity of etchand absence of intergranular attack.

2) A 0.040” x 4“ x 4$’ coupon from 2024-T3.This coupon will be pre-weighed byGeneral Dynamics/Fort Worth DivisionProcess Engineering Development”&Control prior to release and will beused to verify the required metalremoval quantity of 0.0003 to 0.0007inch per surface.

e) For supplier-produced forgings, the .0003inch per surface removal quantity minimumshall be applicable, but the maximum

● allowable removal quantity shall be limitedonly by the dimensional requirementsspecified by the engineering drawing.

4.6.3 For steel etch processes:

a) Chemical composition of proposed solution(s).

b) Etch rates, immersion times, and operatingtemperatures of proposed solutions. Etchrates will be determined for each alloy andheat-treated condition to be processed in thepre-penetrant etch solution.

c) Solution and etch control procedures.

., .,.. . . ,...



d) Results of intergranular attack examinationper Paragraph 4.6.6.

4.6.4 For titanium etch processes:


b) Etch rates, immersion times, and operatingtemperatures of proposed solutions.

c) Solution and etch rate control procedures.

A test report showing that the proposed etchprocess will produce a uniformly etchedsurface without introducing more than 20 ppmhydrogen. Once this proposed etch process isapproved, this test is the suppliersresponsibility to perform on a monthly basis.The titanium test coupon shall be processedalong with a batch of GD/FW parts.

4.6.5

4.6.6

For MP35N, Inconel 625 and Inconel 718 etchprocesses.


b) Etch rates, immersion times and operatingtemperatures of proposed solutions. Etch.rates will be determined for each alloy andheat-treated condition to be processed in thepre-penetrant etch solution.

c) Solution and etch procedures.

d) Results of intergranular attack examinationper paragraph 4.6.6.

All steel alloys, MP35N, Inconel 625 and Inconel718, processed in an alternate etchant shall betested for intergranular attack by the followingprocedure.

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a) After etching, cut two cross-sectionalspecimens. whose outer perimeter contains atleast 0.75 inch of surface material. Polishthe cross-section and examine along theetched edge for intergranular attack. Nointergranular attack shall be visible whenviewed at magnification of 500X.

4.6.7. Unless othewise specified, the requirementsreferred to in paragraph 4.6 shall be satisfied ona one-time qualification basis. If significantchanges are made to the qualified alternate etch,re-qualification will be required. GeneralDynamics/Fort Worth Division Process EngineeringDevelopment & Control reserves the right torequire re-qualification upon request.

4.7 Cleanliness Prior To Penetrant Inspection

4.7.1 It is preferred that parts and materials beinspected as soon as possible after etch. Partsthat must be temporarily stored after etch shallbe covered to prevent collection of dust, dirt andother environmental particles. Contaminated partsshall be re-cleaned.

5.0 INSPECTION PROCEDURE.

NOTE : Refer to NDTS 1101-2 for portable FPIprocedures.

.5.1 -

Penetrant Application and Dwell.

5.1.1 Apply penetrant to all surfaces by dipping,spraying, brushing or flowing. Theparts/materials, penetrant and ambienttemperatures “shall be in the range of 40 deg. F to120 deg. F.

5.1.2 Minimum penetrant dwell time shall be 10 minutes.Allow penetrant to drain from parts during thedwell time. For dwell times greater than 2 hours,the penetrant shall be reapplied, if necessary, toenhance washability.

,-. . . . . . . . . . . . . . . . . . . . . . . ...4. . . . . ,,. . . . . . ...4.!.. . . ,., .,-.., ... ...,.

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5.2 Penetrant Removal.

5.2.1 Water Washable Penetrants:

a) Excess penetrant may be removed by manual orautomated water spray or manual wipe.

b) Penetrant removal shall be accomplished byrinsing with a coarse spray nozzle at amaximum pressure of 40 psi. Watertemperature shall be between 50 deg. F and100 deg. F.

c) Hydro-air nozzles shall be permitted only forLevel 1 and Level 2 sensitivity. The addedair pressure shall be 25 psi maximum.

d) Manual washing shall be conducted underbacklight. Backlight is not required inautomated wash stations.

5.2.2 Solvent Removable Penetrants:

a) First remove excess penetrant with a clean,lint free, dry cloth or absorbent towel. Theremainder of the surface penetrant is thenremoved with a solvent-dampened cloth ortowel. The surface of the component shallnot be flushed with solvent and the cloth ortowel shall not be saturated with solvent.

- Let the part dry by evaporation.

5.2.3 Lipophilic Emulsified Penetrants:

a) Lipophilic emulsifiers shall be applied byimmersion, then allowed to drain. Lipophilicemulsifiers shall not be applied by spray orbrush and shall not be agitated while on thesurface of the component under test. Maximumdwell times, unless otherwise specified,shall be three minutes. After theappropriate emulsifier dwell time,emulsification shall be stopped by waterimmersion or water spray. Complete penetrantremoval per Paragraph 5.2.1.

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5.2.4

5.2.4.1

5.3

5.4

5.4.1

Hydrophilic Remover Systems.

a) A water spray pre-wash shall be used tomechanically remove the bulk of excesspenetrant.

b) Hydrophilic remover shall be applied byspraying, flowing or agitated immersion.

c) Complete penetrant removal per Paragraph5.2.1.

For immersion applications, the concentrationshall be as specified by the manufacturer butshall not exceed 35 percent by volume. For sprayapplications, the concentration shall not exceed 5percent by volume.

Drvinq.

a) Water rinsed parts or materials shall bedried prior to application of dry ornonaqueous developer, or inspection withoutdeveloper.

b) Drying may be accomplished in a re-circulating hot air dryer at a temperaturenot to exceed 160 deg. F.

c) Parts shall not remain in the dryer longer.“than necessary. Excessive time prior todeveloper application will affect sensitivityof the process.

Armlication of Developer.

penetrant inspections to Zone 1A, lB, and lC shalluse a developer unless previously demonstratedwithout developer to Process EngineeringDevelopment & Control. The satisfactory resultsshall be published in the FQPL: NDTS 1101, latestrevision.

6.2

6.3

.



5.4.1.1 Dry Developer.

a) Apply dry developer by electrostaticspraying, dipping, dusting, or pouring.Dwell time shall be 10 minutes minimum and 4hours maximum.

5.4.1.2 Aqueous Wet Developer.

a) Developer shall be applied after rinsing orafter the part is dry. Aqueous developersshall be applied by spraying or momentarydipping.

b) Minimum and maximum dwell times after thedeveloper has dried on the partls surfaceshall be 10 minutes and 2 hours respectively.

5.4.1.3 Non-Aqueous Wet Developer.

a) Non-aqueous wet developer shall be appliedonly to parts and materials which are dry andcool enough to handle.

b) Apply developer by spraying. Inspectionshall take place within 1 hour after non-aqueous wet developer has been applied.

6.0 INSPECTION.

6.1 Par&s not inspected before the maximum developerdwell time shall be cleaned (no pre-penetrant etchrequired) and returned for penetrant inspectionstarting with penetrant application.

Inspection of parts shall be conducted underbacklight in a darkened area. For AUTOMATEDRINSE SYSTEMS: If background fluorescence isunacceptable, a second rinse and air dry ispermitted.

Inspectors shall allow a sufficient time forvision adjustment (dark conditioning) each timethe darkened area is entered from white light, andshall not wear photosensitive, tinted, orpermanently darkened lenses during evaluations.


SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 1101GDATED:. May 21, 1990PAGE: 19

7.0

7.1

ACCEPT\REJECT CRITERIA.

Indications. There are basically two types ofpenetrant indications Linear and Rounded. Linearindications are linear in shape and have a lengththree times or greater than the width. Roundedindications are round in shape. Indications whichare not linear but have discernible pointed orsharp edges are to be considered linear.

7.1.1 Indication Verification. All questionableindications shall be wiped with a solventmoistened cloth, cotton swab, or towel. If theindication persists after wiping it shall beconsidered a relevant indication or discontinuityand shall be evaluated per the followingparagraphs. For discontinuities which touch, theconglomerate size shall be considered as onediscontinuity.

7.2 Discontinuity. If the inspector identifies adiscontinuity as a defect, the defect may beremoved the part evaluated for dimensionaltolerance, and either accepted or rejected. Ifrejected, the part shall be Processed inaccordance with FZM 13725.

7.2.1 Defect Removal. Defect(s) may be removed bysanding or grinding. EXCEPTION: See paragraph7.2.2. After removal the area must be cleaned andreirrspected. If power tools were used to removethe defect(s), the removal area must be 1) cleanedand etched or 2) hand-sanded with 320 grit orfiner and cleaned, and then reinspected.

7.2.2 Parts made from vendor-supplied castings,forgings, etc. that have discontinuity(s) shall beprocessed in accordance with FZM 13725.EXCEPTION: If GDFW caused the discontinuity(s),the discontinuity(s) may be removed andreinspected.


7.3

7.3.1

7.3.2


ZONE Standards. The accept/reject criteriaspecified on the Engineering Drawing is based onthe ZONES specified herein. Final dispositions toreject parts which exceed ZONE allowable shall bebased on the measurement of actual discontinuitysizes. Regardless of Zone Standards lineardefects are not allowed.

NOTE : IRP 0077-2 (Illustrated in Figure 1) may beused as a visual aid in determining approximatediscontinuity sizes based on the Zone criteria.

When no zone number is specified on theEngineering Drawing, ZONE O shall be used as theaccept/reject criteria.

For portions of parts where the thickness is 0.13inch or less, indications that are in-line onopposite sides are rejectable. The inspectorshall use his or her best judgment in determiningwhether the two indications are in-line.

7.3.3 ZONE O and Zone 1: Rounded discontinuities equalto or exceeding 0.02 inches in the maximumdimension shall be rejected. Any twodiscontinuities closer than 0.02 inches shall berejected.

7.3.4

7.3.5

7.3.6

ZONE 1A, lB, lC. The accept-reject criteria areidentical to ZONE 1 for rounded discontinuities.Only-those facilities listed in the currentrevision of FQPL:NDTS 1101, as having successfullycompleted a Penetrant Demonstration Program, shallperform inspections to Zones 1A, lB, or lC. (SeeAppendix “AO’) .

ZONE 2. (EXCEPT FOR CAST SURFACES). Roundeddiscontinuities equal to or exceeding O.O3 inchesin the maximum dimension shall be rejected. Anytwo discontinuities closer than 0.03 inches shallbe rejected.

ZONE 2. (CAST SURFACES). Rounded discontinuitiesequal to or exceeding 0.05 inches in the maximumdimension or any two discontinuities closer than0.05 inches shall be rejected.

,.

.



7.3.7 ZONE 3. Retained for future expansion.

7.3.8 ZONE 4. This zone is intended for inspection ofraw materials surfaces, i.e. as forged, as rolledetc. Indications resulting from surface t

imperfections which are permitted by theprocurement specification are acceptable. Cracksand other linear defects which result from heattreatment, forming or other manufacturingprocesses are not acceptable.

7.3.9 ZONE 5. This zone is intended for areaswhere subsequent processing, such asmachining, etching, grinding, etc., will be usedto remove surface material. Indications resultingfrom rough surfaces, minor pitting, etc., shallnot be cause for rejection providing theconditions are removable within drawingtolerances. Gross defects, such as cracks, laps,seams, cold shuts, etc., are not acceptable. Ifthese conditions are removable within tolerances,parts can be accepted.

7.3.10 ZONE 6. This zone is intended for as-castsurfaces which remain on the finished part ofaircraft quality castings. Use the sameaccept/reject criteria in ZONE 2 (CASTINGS) .

7.4

7.5

8.0

8.1

8.2

Unless otherwise specified by Engineering,acceptance criteria in FPS-1097 shall be appliedto all welds.

The P.S. 92.01-1 (MIL-STD-41O) Level III PenetrantInspector shall be the final authority in cases of~estionable interpretation.

POST-INSPECTION REQUIREMENTS.

Defects shall be marked on the part and/oridentified on the rejection paperwork as toapproximate location and dimension. Markings usedshall not be detrimental to the part.

Residue from the penetrant inspection (e.g.,Penetrant, developer, etc.) shall be removed.

.

,



8.2.1 If wet developers are used and parts are to bestocked prior to further chemical surfacetreatment, these parts shall be alkaline cleanedin an inhibited cleaner (non-etching) followed byrinsing, acid cleaning, then final rinsing anddrying. Manual wiping with solvent cleaner may benecessary to aid final cleaning process.

8.3 Post-inspection clean-up operations which requireminor surface metal removal do not require asubsequent etch/penetrant cycle provided the partswere previously pre-penetrant etched, penetrantinspected, and found acceptable. Such operationsare limited to the following:

a) Removal and re-application of vibro-engravedmarkings.

b) Smoothing of isolated areas of surfaceroughness not in compliance with drawingrequirements.

c) Removal of minor amounts of excess metal,such as flash and chill marks.

d) Cosmetic improvement of other surfaceconditions not related to removal of lineardefects; excluding gating, risers, weldmentsor other similar instances where removal ofconsiderable materials would be involved.

.9.0 -

9UALITY ASSUlU4NCE PROVISIONS.

9.1 This section provides the controls necessary toassure that the penetrant system materials andequipment provide an acceptable level ofperformance. The frequency of checks may bealtered provided a plan justifying this change isprepared by the NDT facility and approved byGeneral Dynamics/Fort Worth Division ProcessEngineering Development & Control. The NDTfacility may perform these process controloperations or contract for their performance withan independent laboratory.

. .

.



9.2

9.3

Blackliuhts. All backlights shall be checkeddaily, and after bulb replacement, for output.Minimum acceptable intensity is 800 microwatts/square centimeter measured at a distance ofat least 38 cm (15 inches) from the front of thebulb or filter.

White Liuht. The inspection area shall be checkedfor white light incursion. This check shall beperformed weekly to assure it does not exceed twofoot-candles.

9.4 Process Performance.

9 . 4 . 1 The entire penetrant inspection system shall betested once a week for detectability andbackground. The record of these” results shall bekept for review. Significant changes shall beinvestigated and corrective, action taken.

9.4.2 GDFW shall use a Penetrant System Monitor (PSM)which is a cracked chrome panel containing crackson one half of the panel and the other half gritblasted (medium roughness). The following areacceptable PSM’S:

Pratt and Whitney Tam Panel P/N 146040Sherwin Company P/N PSM - 5Magnaflux Corp. P/N 198055

9.4.2.1 The.PSM shall be processed through all GDFWpenetrant systems using appropriate processingparameters. A comparison shall be made between aPSM panel freshly processed through the penetrantinspection system and a second PSM (standard)freshly processed through a manual system usingunused penetrant materials. Significant changesin detectability and/or background shall bereported to Process Engineering Development &Control.

NOTE : A photograph is an acceptable substitutefor the PSM standard. The photograph shall beapproved by a GDFW penetrant level III and QualityControl.

. . . . .. *

.

“GENE~L DYNAMICSFORT WORTH DIVISIONCode Identification 81755


9.4.2.2

9.5

9.5.1

9.5.2

9.5.3

9.6 -

9.6.1.

After comparing the processed PSM panels theyshall be cleaned immediately by vapor decreasingor ultrasonic cleaning. An acceptable alternativeis to wipe with a chlorinated hydrocarbon solventfollowed by a 4 hour soak in the solvent. Do notclean specimens with a brush. The PSM panel mustbe clean, dry and free of any solvent or penetrantresidue. Each PSM panel shall be checked forcleanliness under backlight before reuse.

Materials. Materials will be selected from MIL-I-25135 Qualified Products List. Operators shallreport any changes in performance, color, odor,consistency or appearance of all penetrantmaterials in use. Process Engineering Development& Control shall conduct .the appropriate tests onmaterials suspected of being substandard.

New (unused) materials do not require periodicchecks.

Unused materials shall be stored in a temperature-controlled environment between 40 and 150 deg. Fmaximum. If the temperature decreases below orincreases above this range, the penetrant must beretested in accordance with paragragh 9.6.

Penetrant materials stored more than five yearsshall be retested in accordance with paragraph9.6. .

Penetrants. The following checks on in-usepenetrants shall be conducted at least monthlywith the exception of brightness which shall beconducted at least quarterly. Unsatisfactoryperformance shall be cause for replacement of thein-use material or corrective action asappropriate.

Bri~htness. Brightness tests of in-use penetrantsshall be conducted in accordance with MIL-I-25135with a sample of the unused penetrant serving asthe reference. Brightness values less than 90percent of the unused penetrant brightness areunsatisfactory.

.,.

z



9.6.2 Water Content. (Water washable penetrants only).Water content of Method A penetrants in dip tanksshall be measured in accordance with ASTM D 95.Water content in excess of 5 percent by volume isunsatisfactory.

9.7 Emulsifiers\Removers. The following checks on in-use emulsifiers/removers shall be performed asspecified. Unsatisfactory performance shall because for replacement of the in-useemulsifier/remover or corrective action asappropriate.

9.7.1 Removability. Removability of the in-useemulsifier/rernover shall be checked weekly inaccordance with MIL-I-25135. The in-useemulsifier/remover will be used with the unusedpenetrant and compared to the reference system ofunused emulsifier/remover used with the unusedpenetrant. Removability less than that of thereference system is unsatisfactory.

9.7.2 Water Content. (lipophilic emulsifier). Watercontent shall be checked monthly in accordancewith ASTM D 95. Water content in excess of 5percent is unsatisfactory.

9.7.3 Concentration (hvdroRhilic removerl.Concentration of immersion solutions shall bechecked weekly with a refractometer. Variation ofconcentration greater than three percentage pointsfrom the initial, unused concentration isunsatisfactory. Spray concentrations shall bechecked weekly with the refractometer and shallnot exceed the specified manufacturer’sconcentration for the system.

9.8 Develo~ers. The following checks on in-usedevelopers shall be performed as specified.Unsatisfactory performance shall be cause forreplacement or corrective action as appropriate.

\. . .

?

GENE~L DYNAMICSFORT WORTH DIVISIONCode Identification 81755


9.12 If specified, parts which have been inspected byFPI shall be marked in accordance with theapplicable drawing, specification or purchaseorder. If marking method is not specified,marking shall be in accordance with FPS 3008,Class II, applied in a manner and location that isharmless to the component, or its intendedfunction, and to preclude removal, smearing orobliteration by subsequent handling. Plated partsand parts that receive subsequent processing thatwill remove the identification shall be identifiedby marking the records that accompany the parts.

9.12.1 Suppliers and coproducers that perform subsequentprocessing shall identify parts with a penetranttransfer stamp or equivalent after processing iscomplete. (Applies to details delivered to GDFWonly]

10.0 DEFINITIONS.

Black Liuht. The term given to electromagneticradiation having wavelengths between 2000 and 4000Angstrom units. Typical units used in penetrantinspection provide a minimum intensity of 800micro-watts/square centimeter at 38 cm (15 inches)from the face of the filter and are used to excitefluorescent materials in a range visible to theeye.

Defects. Discontinuities which a) interfere withthe usefulness of a part, or b) contain faults inthe material which are detrimental to itsserviceability, or c) exceed Engineeringspecification/tolerances.

Develo~er. Material, wet or dry, which will drawor absorb penetrant from a surface crack or defectto the extent that the defect will be visibleunder black light.

Discontinuities. The interruption in the normalphysical structure or configuration of a part suchas cracks, lapS, SeamS, inclusions, scratches,porosity, etc. A discontinuity may or may notaffect the usefulness/serviceability of a part.

-..

?



Emulsifier. A liquid agent which must be appliedto the non-water-washable penetrant after theproper dwell time has elapsed to permit waterrinsing. This requires an additional step and aperiod of time must be allowed for the combiningto occur. A suspension of one liquid phase inanother.

Etchinq. Subjecting the surface of a metal topreferential chemical or electrolytic attack inorder to reveal structure/defects.

Fluorescent Denetrant ins~ection (FPI). ISperformed after all fabrication/processing iscompleted.

Hiuh Tem~erature Allovs. Nickel, tungsten,columbium, and cobalt based alloys.

Hvdro~hilic. Having an affinity for, attracting,adsorbing, or absorbing water. A substancesoluble in water.

Hvdro~hilic Remover. A water compatible removerused with standard penetrants. Provides forimproved control for the emulsification process.It requires different processing steps than thestandard lipophilic emulsifiers.

Indications. The visible evidence of penetrantwhich has come out of a discontinuity, indicatinga surface opening is present. Indications whichtouch shall be considered as one indication.

Linear Indications. Indications havingsharp/pointed edges and whose length is more thanthree times their width.

LiDo~hilic. Relating to or having a strongaffinity for fats or other liquids: Promoting thesolubilization or absorption of lipids. An oil orfat based substance.

. . . . . . . . . . . . . . . . . . . . . . . . . . .. .

*

GENERAL DYNAMICSFORT WORTH DIVISIONCode Identification 817S5


Machined. Metal removal by mechanical powertools, such as milling, turning, spot-facing,counterboring, countersinking, sanding, androuting.

Penetrant. A liquid of high surface tension andhigh capillary action which is a vehicle for acolored or fluorescent dye, used to penetrate intoand detect surface discontinuities.

Penetrant Sensitivity. Penetrant sensitivity isthe ability of the penetrant, processingtechnique, and developer to detect surface -connected discontinuities and provide anindication visible to the unaided eye.

Process Control. A general term used to encompassthe actions and documentation, as required byofficial directives or logic, that are necessaryfor an NDI method to be effective in detectingconditions of interest (e.g., cracks, foreignobjects, corrosion, alignment of parts, thicknessof parts/coating, and pressure/vacuum leaks) .

Processing. Operation to convert raw material toa finished product.

Rounded Indications. Indications which haverounded edges and whose length is less than threetimes their width..

Wrouuht Products. All forms except castings.



FIGURE 1

Print of IRP 0077-2, Visual Aid/Standard ForFPI of Rounded Indications

IRP~s are available from Process EngineeringDevelopment and Control General Dynamics/Fort WorthDivision


SPECIFICATION NDTS 1101REVISICIN: HDATED: June 21, 1991SUPERSEDES: NDTS 11OIGDATED :PAGE :

A P P E N D I X “ A “

PRODUCTION PENETRANT DEMONSTRATIONl~ZONE 1A, lB, AND lC~l CRACK DETECTION

May 21, 1990Al

PROGRAMCAPABILITY

The following program is established per MIL-A-83444 todemonstrate the capability of liquid penetrant inspectionfacilities to detect cracks in selected materials with 90%probability of detection at a confidence level of 95%.

Test S~ecimens

Fatigue cracked specimens fabricated for the GeneralDynamics/Fort Worth Division Penetrant Demonstration Program willbe used. A backup set of specimens will be available if needed.

The production liquid penetrant materials, procedures andcertification program of each facility processing parts whichrequire ZONE 1A, lB, or lC criteria shall be approved by GeneralDynamics Process Engineering Development and Control.

At least two certified (Level II or Level III per MIL-STD-410) penetrant inspectors at each facility shall participate inthe inspections. Each inspector will process sufficientspecimens so that the total inspections per facility will be atleast 30 defect and 15 control specimens for a specific cracksize. If sufficient misses occur, the backup specimens will beutilized to obtain more data and increase the probability ofsatisfying the program requirements.

The inspectors will process the specimens per approvedprocedures and document their findings on inspection formsprovided. The tests will be witnessed by a General Dynamics/FortWorth Division Process Engineering Development and Controlrepresentative who will evaluate the results.

Cleaning of specimens between inspections will be directedand monitored by the General Dynamics/Fort Worth Divisionrepresentative utilizing available equipment at each facility.Cleaning may be accomplished by vapor-degreasing, solventimmersion, or other methods determined by the GeneralDynamics/Fort Worth Division representative.


SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990PAGE: A2

PRIMARY

BACK-UP

RESULTS

1.

2.

3.

ZONE

1AlBlC

1AlBIC

DEFECTSPECIMEN

303030

151515

QUALITY CONTROLSIZE SPECIMEN

. 100 15

.050 15

.040 15

.100 5

.050 5

. 040 5

SIZERANGE

.090-.100

.045-.055

.035-.044

. 090-.100

.045-.055

.035-.044

If all 30 primary defects are correctly detected, thefacility will be approved.

If one primary defect is missed by either inspector andall back-up defects are detected, the facility will bequalified.

If more than one defect is missed, the facility willnot be qualified. The penetrant materials/system mustbe changed and/or additional training must be conductedbefore the inspection sequence can be repeated.

Statistical procedures are based on the Binomial ReliabilityTable, Naval Weapons Report No. 8090, C“hina Lake, California,1964. .

GENEWiL DYNAMICSFORT WORTH DIVISIONCode Identification 81755

SPECIFICATION NDTS 1101REVISION: HDATED: June 21, 1991SUPERSEDES: NDTS 1101GDATED: May 21, 1990PAGE: B1

APPENDIx B

TEST FREQUENCIES

TEST

Black Light

Process Performance

Brightness

Water Content (Penetrant)

Sensitivity

Removability (Emulsifier)

Water Content

Concentration

Dry Developer

Concentration

White Light

(Emulsifier)

(Emulsifier)

(Developer)

.Pressures/Temperatures

FREOUENCY

Daily

. Weekly

- ,Quarterly

Monthly

Bi-Annually

Weekly

Monthly

Weekly

Daily

Weekly

Weekly

Beginning of EachOperational Shift

.

GENERAL DYNAMICS Amendment 2 to NDTS 1101 H (qFort Worth Division Date: 17 February 1993.FSCM 81755 Superseding: Amendment 1

AMENDMENT TONDTS 1101H


Contract Numtw: F33857-84-C-0247

Releasability of this material under the Freedom ofInformation Aot is subject to the restrictions on release inDoD Regulation 5400.7-R and DoD Directive 5230.25.

GENERAL DYNAMICS Amendment 2 to NDTS 1101HC2

, FOII Worth Division Date: 17 February 1993FSCM 81755 Superseding: Amendment 1

Prepared By:

<-i oLJzw--T. L. C6?istensonNondestructive EngineeringDevelopment


Approved By:

D. M. Duncan, ChiefNondestructive EngineeringDevelopment

S. B. Kiehl, ChiefMetals & High TemperatureMaterials & Processes .

*N“DE and Sensors Development

GENERAL DYNAMICS Amendment 2 to NDTS 1101 H. Fort Worth Ditision Date: 17 February 1993

FSCM 81755 Supersedin$y Amendment 1

This amendment forms apart of and shall be attached to General Dynatics/Fort Worth DivisionStandard NDTS 110IH, Penetrant Inspection, dated July 3, 1992. This amendment shall becomeeffective immediately upon issue.

7.0 to 7.4 Reaaon for Amendment 2: Replace paragraphs 7.0 to 7.4 and revise paragraph& 3.4.4 3.4.4, TABLE 1, to adequately define accept/reject criteria.

3.4.4

7.0

7.1

7.1.1

7<1.1.1

7.2

7.2.1

7.2.2

MI! I ?5135 ~. . .. .

33

1

TABLE 1

All Tdanium and High Temperature AlloysMachine Surfaces (Afl Wrought Materials except forAluminum)All other surfaces including welds which are notcovered above

ACCFPTIRFJ=T CRITEEM

~- There are two types of penetrant indications, linear and rounded. Linearindications are linear in shape and have a length three times or greater than the width.Rounded itilcations are round in shape. Rounded indications which are jagged shall beconsidered round.

. . . . .~ - For a rounded indication to be rejectable, it must be visible underblack light. All questionable rounded indications shall be wiped with a solvent moistenedswab, cbth, or towel and non-aqueous developer applied. If the indication persists after amaximum of three wipes and developments, it shall be considered a relevant inrlcation ordiscontinuity and shall be evaluated per the following paragraphs. Unless otherwisespecified by Engineering, acceptance criteria for welds shall be per FPS-1 097.

P -. . - For discontinuities which touch, the conglomerate size shall beconsidered as one discontinuity. Discontinuities whose separation distance is equal to orcbser than zone criteria size (see below) and which are visible under black light, shall berejected regardless of individual size.

~- The acceptkeject criteria for rounded discontinuities specified on theEn$@eering Drawing is based on the zones specified herein. When no zone nutier isspecified on the Engineering Drawing, Zone O shall be used as the acceptlreject criteria forrounded discontinuities. The final decision to reject parts which exceed zone aliowablesshafl be based on the measurement of actual discontinuity sizes. IRP 0077-2 (illustrated inFigure 1) or transparent comparators maybe used as a visual aid in determiningapproximate discontinuity sizes based on zone criteria. REGARDLESS OF ZONECALLOUTS, LINEAR DEFECTS ARE NOT ALLOWED WHETHER VISIBLEUNDER WHITE LIGHT OR BLACK LIGHT.

7nne O ~ - Rounded discontinuities equal to or exceeding 0.02 inches shall berejected.

4(33

1

GENERAL DYNAMICS Amendment 2 to NDTS 1101 H C4,Fort Worth Division Date: 17 February 1993FSCM 81755 Superseding: Amendment 1

7.2.3

7.2.4

7.2.5

7.2.6

7.2.7

7.2.8

7.2.9

7.3

7,4

ZglW - (EXCEPT FOR CAST SURFACES). Rounded discontinuities equal to orexceeding 0.03 inches shall be rejected.

ZflllOJ - (CASTINGS). Rounded discontinuties equal to or exceeding 0.05 inches shallbe rejected.

ZQ,DXI - Reserved for future use.

m-TM zone is intended for inspection of raw materials surfaces, i.e. as forged, asrolled, etc. Discontinuities resulting from surface inqxrfections which are permitted by theprocurement specification are acceptable.

Z#125 - This zone is infetied for areas where subsequent processing, such asmachining, etching, grinding, etc., will be used to remove surface material. Discontinuitiesresulting from rough surfaces, minor pitting, etc., shall not be cause for rejection providingthe condtiions are removable within drawing tolerances,

_- This zone is intended for as-cast SWfacOS which remain on the finished part ofaircraft quaiii castings. Use the same accept/reject criteria in Zone 2 (CASTINGS).

zone 1A. 1 B. lQ - The designation of Zones 1A, 1 B, or lC are reserved for primarystructural parts, e.g. Fatigue and/or Fracture Critical patts. The suffix A, B, or C designatesthe level of facility qualification. A parl requiring one of these Zones requires anaccept/reject decision to Zone 1 criteria. Only those facilities that have successfullycompleted the Production Penetrant Demonstration Program per Appendix “A” shallperform inspections to 1A, 1 B, or lC.

v Fvaf@QR - If the inspector identifies a discontinuity(s), the discontinuity(s)may be lightly hand sanded with 120 grit or finer sand paper, the pan evaluated fordimensional tolerance, and either accepted or rejected. A discontinuity(s) need only besanded to the extent that the zone criteria are met. if rejected, the part shall be processedin accordance with FZM 13725.

~: Defect(s) maybe reworked by sanding or grinding to the extent of beingacceptable per zone albwables. ~defects which have been reworked shall bechecked either visually under magnification or cleaned, and penetrant inspected (etch notrequired). A linear defect(s) which has been reworked shall be locally etched, cleaned,and re-penetrant inspected.

2

LOCKHEED Amendment 3 to NDTS 1101 H C5. Fort Worth Company Date: 29 September 995FSCM 81755

AMENDMENT 3 TONDTS 110IH,


Contract Number: F33657-88-C-O037

Releasability of this material under the Freedom of Information Act is subject to therestrictions on release in DoD Regulation 5400.7-R and DoD Directive 5230.25.

,0/

LOCKHEED Amendment 3 to NDTS 1101 H Lo

Fort Worth Company Date: 29 September1995FSCM 81755

This amendment forms a part of and shall be attached to LOCKHEED Fort Worth Company SpecificationNDTS1 101 H, PENETRANT INSPECTION, dated 21 MAY 1990. This amendment is effectiveimmediately upon issue.

PAGE 9Para. 4.3.1

PAGE 9Para, 4.3.1(c)

PAGE 9Para. 4.3.2

PAGE 11Para. 4.5

Para. 4.5.1

Para. 4.5.2

Change:

Change:

Change:

Reason:

Change:

Change:

Change:

Reason:

PAGES 12, 13, 14, and 15

PREPARED BY:

Delete “corrosion resistant steels (excluding 400 series) which have” andinserf “3oO series corrosion resistant steel which has”.

Delete “corrosion resistant steels (excluding 400 series)” and insert “300series corrosion resistant steel”.

Delete “CRES steels” and replace with “300 series CR ES”

To exclude CRES materials other than 300 series CRES from thepre-penetrant etch requirements since the motivation for conductingpre-penetrant etching of those materials has gone away. This shouldeliminate future REA’s of the same type as MG64746, MG64754, and64760.

Delete paragraph.

Delete paragraph.

Delete paragraph, including sub-paragraphs a), b), and c).

To exlclude nickel based alloys from the pre-penetrant etchrequirements since the motivation for conducting pre-penetrant etching ofthose materials has gone away. This should eliminate future REA’s ofthe same type as MG64746, MG64754, and 64760.

Change: Decrement paragraph numbers of paragraphs 4.6,4.7, and allassociated sub-paragraphs by one.

Reason: To account for the fact that paragraph 4.5 was deleted.

M H?4&(’M.L. PoileyStructural and EnvironmentalMaterials and Processes

APPROVED BY:

J%LLUGS.B. Kiehl, ChiefStructural and EnvironmentalMaterials and Processes

1

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