UK National Aerospace NDT Board Recommended Guidance for NDT Personnel Requiring Certification for Inspection of Composite Materials Presentation complied by UK NANDTB Composites Ad-hoc Working Group 1 NAndtB_19 Issue

UK National Aerospace NDT Board Background  The Composites Task Group at their meeting on 22 nd January 2009 agreed the principle such that under EN4179 the Responsible Level 3 should determine any additional training and certification for inspections on composite materials/structures.  However, the group acknowledged that many Responsible Level 3’s may not hold the management authority to specify additional training and examinations, even though they may determine them as necessary.  Experience within the group has shown, that unless the Responsible Level 3 can show management specific regulatory requirements, then often requests for additional training/certification are denied.  The sub group agreed that published guidance from the NANDTB would assist the Responsible Level 3 not only to determine any additional training/certification required, but to gain the necessary financial support from management. NAndtB_19 Issue

UK National Aerospace NDT Board Content  Composite material definitions.  Applicable NDT methods and techniques.  Recommended guidance for NDT training & approval of personnel. NAndtB_19 Issue

UK National Aerospace NDT Board Composite Material Definitions  Composite Material  Polymer Matrix Composites  Fibre Metal Laminates  Sandwich Structures  Metal Matrix Composites  Ceramic Matrix Composites  Bonded Structures  Responsible Level 3’s should be aware that although this list of composite materials definitions is extensive, it should not be considered exhaustive. NAndtB_19 Issue

UK National Aerospace NDT Board Composite Material  A combination of two or more materials, differing in form or composition on a macro scale. The constituents retain their identities; that is, they do not dissolve or merge completely into one another although they act in concert. Normally, the components can be physically identified and exhibit an interface between one another. See ISO 472. Composite materials are usually man-made and created to obtain properties that cannot be achieved by any of the components acting alone. NAndtB_19 Issue

UK National Aerospace NDT Board Polymer Matrix Composites  Generally polymer matrix composites in aerospace applications have glass or carbon fibres with an epoxy matrix. However, other fibre reinforcing materials such as boron and Kevlar are available as other types of matrix polymers for example polyester, phenolic, polyimide, polyamide and PEEK. NAndtB_19 Issue

UK National Aerospace NDT Board Fibre Metal Laminates  Materials consisting of alternating layers of unidirectional continuous fibre and thin metal sheets bonded together with a polymer. Examples of FML’s are GLARE (Glass fibres, aluminium alloy sheets bonded with an epoxy) and ARALL (Aramid fibres, aluminium alloy sheets bonded with an epoxy). NAndtB_19 Issue

UK National Aerospace NDT Board Sandwich Structure  Metallic or monolithic composite skins/faces adhesively bonded to a core material, which may be honeycomb, foam, or balsa. Honeycomb cores can be metallic, paper, or resin impregnated paper (Nomex). There are various polymer based foam core materials. NAndtB_19 Issue

UK National Aerospace NDT Board Metal Matrix Composites  A dispersion of reinforcing material, which may be short or long fibres or particulate in nature, in a metallic matrix. Examples; long fibre reinforcing materials include boron, graphite (carbon), alumina, and silicon carbide; short fibre materials are alumina, alumina-silica, silicon carbide and boron carbide; particulate reinforcing materials include alumina, tungsten carbide and yttria. NAndtB_19 Issue

UK National Aerospace NDT Board Ceramic Matrix Composites  A dispersion of reinforcing material, which may be short or long fibres or particulate in nature, in a ceramic matrix. NAndtB_19 Issue

UK National Aerospace NDT Board Bonded Structures  Structures/components that are fabricated by adhesively bonding, excluding sandwich structures, these include metal to metal, composite to composite, or combinations there of. NAndtB_19 Issue

UK National Aerospace NDT Board Applicable NDT Methods/Techniques NAndtB_19 Issue These are commonly applied NDT methods/techniques applied to composite and bonded structures, the list is not all inclusive and training and qualification of NDT personnel using other methods/techniques must be considered by the Responsible Level 3. Ultrasonic Testing Automated immersion or modified immersion (Jet Rigs) Reflector Plate C-Scan Through Transmission C-Scan Pulse echo (Phased Array) C-Scan Array probe (paintbrush) Pulse Echo C-Scan Pulse Echo B-Scan Pulse Echo Full Waveform Capture Ultrasonic Testing Manual Contact Pulse Echo A-Scan Through Transmission A-Scan (Air, dry & water coupled) Pulse Echo B-Scan Pulse Echo C-Scan Phased Array Array probe (paintbrush) Ultrasonic Testing Non-linear techniques

UK National Aerospace NDT Board Applicable NDT Methods/Techniques NAndtB_19 Issue These are commonly applied NDT methods/techniques applied to composite and bonded structures, the list is not all inclusive and training and qualification of NDT personnel using other methods/techniques must be considered by the Responsible Level 3. Low Frequency Acoustic testing Manual or instrumented Tap Testing Instrumented bond testers Resonance Pitch/catch Mechanical impedance analysis (acoustic flaw detection) Eddy Sonic Radiographic TestingFilm Computed Tomography Digital/Real Time/In Motion Capture ThermographyFlash Lock in Thermosonic/vibro Pulsed/passive LCD

UK National Aerospace NDT Board Applicable NDT Methods/Techniques NAndtB_19 Issue These are commonly applied NDT methods/techniques applied to composite and bonded structures, the list is not all inclusive and training and qualification of NDT personnel using other methods/techniques must be considered by the Responsible Level 3. Laser ShearographyThermal activation (heat simulated) Vacuum activation (vacuum hood) Sonic activation Laser ultrasound Microwave Eddy Current Testing

UK National Aerospace NDT Board Recommended Guidance NAndtB_19 Issue Responsible Level 3 reviews NDT personnel training and approval need versus requirement (1) and application (2) Refers to guidance provided by UK NANDTB/19 Individual who needs to be initially certified in a NDT method/technique for inspection of metallic and composite materials Scenario 3 Individual who needs to be certified in a new NDT method for inspection of composite materials Scenario 2 Individual who holds existing certification in a NDT method/technique for metallic materials Scenario 1

UK National Aerospace NDT Board Scenario 1 NAndtB_19 Issue Existing certified individual needs certifying in application of method/technique to composite materials Did previous training include composites? Additional experience as deemed necessary by the Responsible Level 3, minimum 10% of standard minimum Yes Individual considered competent to perform method/technique on composite material Have relevant specific & practical examinations been successfully completed? Was previous training relevant to intended application? Yes No Additional formal training required via BINDT accredited organisation Individual requires specific & practical examination via BINDT accredited organisation Individual successfully completes examinations

UK National Aerospace NDT Board Scenario 2 NAndtB_19 Issue Individual needs certifying in new NDT method for composite inspection Is method within EN4179 scope? Minimum Experience as required by the standard or NANDTB/14 Yes Individual considered competent to perform NDT method on composite material No Refer to UK NANDTB/14 Comply with requirements of the standard

UK National Aerospace NDT Board Scenario 3 NAndtB_19 Issue Individual needs initial certification in NDT method/technique for metallic and composite material inspection Training requires additional formal hours to standard minimum How many additional hours? 50% of minimum for the method What are the examination requirements? Min 2 samples per technique/material* Individual considered competent to perform NDT method/technique on metallic and composite materials Standard 30 questions minimum COVERING FULL SCOPE OF ACTIVITY SpecificGeneral Standard 40 questions minimum * i.e. metallic and composite Minimum Experience as required by the standard Practical