FAA Update 2015 A4A NDT Forum

I learn from you!! Why are we here? Information Sharing; Provide information and updates for NDI New guidance, i.e. NDI facilities, NDI training and qualification NDI Job Aid I learn from you!! What are you experiencing in the field? What do you see as additional guidance needs? I value your input!!!!

Personnel Changes AFS-300, Steven Douglas, Retired Timothy Shaver acting AFS-301A, Ken Kerzner, Retired Rolandos C. Lazaris AFS-301B, Carol Marteneau, retired Anthony Janko Rusty Jones Flight Standards to Aircraft Certification

FAA Concerns: Qualified inspectors, Differences between composites and metals Training curriculum needs Experience needs Industry Standards ASI knowledge of NDI ACO Engineer NDI

FAA Initiatives AVS Composite Team AVS Additive Manufacturing Team Seven Year Look Ahead Blessed by AVS-1 Composite projects such as: Continued Operational Safety Certification Efficiency Workforce Education AVS Additive Manufacturing Team Commonly referred too as 3-D Printing Road map for guidance & regulations

New/Revised Guidance AC 65-31B: Training, Qualification, and Certification of Nondestructive Inspection Personnel AC 25-29: Development of a Nondestructive Inspection Program/Organization FAA Order 8900.1:  Inspect a Nondestructive Inspection Program/Facility Nondestructive Inspection for Aviation Safety Inspectors Online Job Aid,

AC-65-31B Definitions: revised definitions of; a. Certification b. Certification Based On Previous Experience c. Practical Examination d. Qualification Certificate Added a sentence to state that AIA-NAS-410 and prEN 4179 are harmonized documents. Removed reference to Appendix A which was course outlines for curriculums. Added Thermography as a method. Removed reference to visual so as not to imply that certification/qualification is required for visual inspection.

AC-65-31B Qualifications: Added a Note to clarify that there is not a need to differentiate between metals and composites but that curriculums should be adjusted accordingly. Clarified “grandfathering” based on previous experience and documentation required. Clarification to “Level I Special qualification.(may need additional clarification) Revised Table 1 to include Thermography and reference to additional methods. Clarification of qualification based on previous experience Examination: Clarified color perception requirements. Clarified Practical Examination requirements Clarified FAA certification

NDI Organization Policy and Procedures AC 25-29:Development of a Nondestructive Inspection Program/Organization Five General Elements of an NDI Organization Documentation. Organization Environment Calibration Training Recommendations Pertaining to the Six Most Common NDI Methods. NDI Organization Policy and Procedures

FAA Order 8900.1: Inspect a Nondestructive Inspection Program/Facility This section provides guidance for inspecting a nondestructive inspection (NDI) program and/or facility. This section also provides a link to an online job aid that can assist you, an aviation safety inspector (ASI), in performing a standardized approach for surveillance.

Nondestructive Inspection for Aviation Safety Inspectors Online Job Aid The Aircraft Maintenance Division (AFS-300),designed this job aid to provide a standardized approach to evaluate an NDI organization We provide this job aid as a tool . . . ASI’s shouldn’t use this job aid as a pass/fail checklist form during onsite visits. Part I includes a general section to record pertinent information about the facility. Part II includes specific questions for the six most commonly used methods:

ATA Spec 105 versus AIA NAS-410 Human nature desires to adopt benefits and not take penalties. NAS-410 is more specific as to limitations for a Level I Special. Some operators use Level I Special as a Level I which was never the intent. OEM’s develop procedures with the intent that they would be utilized by at least a Level I

Composite NDI Training Workshop This workshop was convened to discuss the FAA’s Composite Inspector Training activity. The overall objective of this training initiative is to improve the performance of current composite inspection practices. The Composite NDI curriculum can be used by airlines and MROs to enhance an inspector’s preparation and training by focusing on the unique challenges associated with composite laminate inspections. The purpose of the workshop was to obtain input on the needs, objectives, content and implementation of the course that we are trying to develop. Workshop participants include airlines, cargo, MROs and aircraft manufacturers.

Composite NDI Training Workshop NDI training needs (unique composite inspection challenges), Course content (teaching points), needs for hands-on exercises and NDI Proficiency Specimens (training), Human factors issues, use of real life inspection cases, How to best aid/improve NDI methods/procedures, information gathering needed, Training deployment and adoption into airline maintenance programs

Additional FAA Updates: STC ICA’s involving NDI 14 Code of Federal Regulations §21.50 Requires Instructions for Continued Airworthiness Bonded Repair Size Limits Inability to nondestructively measure bond strength is a limiting factor for repair sizes. Challenge: Means to nondestructively but accuratley measure bond strength. Additive Manufacturing What are failure modes? Inspection Challenges Encouragement for young people to enter the aviation maintenance profession

I learn from you!! Why are we here? Information Sharing; Provide information and updates for NDI New guidance, NDI facilities, NDI training and qualification NDI Job Aid I learn from you!! What are you experiencing in the field? What do you see as additional guidance needs? I value your input!!!!