EMAIL: milton.ballesteros@amaszonas.

com
AP--763

NONDESTRUCTIVE TESTING MANUAL

WITH PROCEDURES FOR

FOR

GENERAL INFORMATION (32--42--03)

ULTRASONIC INSPECTION (32--42--04)

EDDY CURRENT INSPECTION (32--42--05)

MAGNETIC PARTICLE INSPECTION (32--42--06)

PENETRANT INSPECTION (32--42--07)

FOR

ALL AIRCRAFT BRAKING SYSTEMS CORPORATION

WHEEL ASSEMBLIES AND BRAKE ASSEMBLIES

AMASZONAS S.A.

BASIC ISSUE MAR 18, 1994

REVISION 1

© ABSC 2005 ALL RIGHTS RESERVED

PUBLICATIONS DEPARTMENT
AKRON, OHIO 44306--4186 (RELEASED: 3/1/05 ) Mar 01/05
CO: 8080

CAGE CODE OB9R9

SEE EXPORT COMPLIANCE PARAGRAPH REVERSE SIDE.

 EMAIL: milton.ballesteros@amaszonas.com
EXPORT COMPLIANCE
These commodities, technology or software were exported from the United States in accordance with the Export
Administration Regulations. Diversion contrary to U.S. law is prohibited.

AMASZONAS S.A.
CO: 8080
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TO: HOLDERS OF AP--763 (GENERAL INFORMATION 32--42--03, ULTRASONIC INSPECTION

32--42--04, EDDY CURRENT INSPECTION 32--42--05, MAGNETIC PARTICLE INSPECTION
32--42--06 AND PENETRANT INSPECTION 32--42--07) NONDESTRUCTIVE TESTING MAN-
UAL WITH PROCEDURES.
Attached to this transmittal letter is Revision No. 1 of AP--763 (basic issue dated 18 March 1994).
REVISION NO. 1 DATED MARCH 01, 2005

HIGHLIGHTS
REVISION NO. 1 CONTAINS ALL PAGES OF THE MANUAL. Pages which have been added or re-
vised are outlined below, together with the Highlights of the revision.

Please retain all previous HIGHLIGHTS pages inserting them into this manual for future reference.
The purpose of Revision No. 1 is to update the information and add in the Temporary Revision No.
1.

Chapter/Section/Page No. Description of Change

Title Page Revised date to current revision date.

Record of Revisions Added Revision No. 1.

page 1

Record of Temporary Revisions, Added Temporary Revision 32--1.

page 1

Service Bulletin List, No Service Bulletins affected this manual.

page 1

List of Effective Pages, Revised to reflect added, revised, and/or deleted pages.
pages 1 and 2

Table of Contents, Updated Table of Contents.

pages 1 and 2

Introduction, Revised to latest Introduction and current field office address list.
pages 1 through 4

All pages Changed “refer to figure” to “see figure”.

(32--42--03 )
AMASZONAS S.A.

General Information

Part 1, pages 1 and 2 Changed the Specification MIL--STD--6866 to ASTM E1417 and
added the Specification NAS--410. Removed reference to “wheel”
in tie bolts.

Highlights
CO: 8080

Page 1 of 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

Chapter/Section/Page No. Description of Change

Part 1, page 3 Updated Figure 1.

Part 1, page 4 thru 6 Consolidated all equipment/material vendor addresses in the

General Section.

Part 1, page 6 Added paragraph to direct users to the World Wide Web site for the
American Society for Nondestructive Testing for additional infor-
mation and vendors for materials and supplies.

(32--42--04 )
Ultrasonic Inspection

Part 2, Procedure 1, page 1 Changed the frequency specification from “mHz” to “MHz” for all
cases. Updated paragraph 2.B.(4).

Part 2, Procedure 1, page 2 Changed paragraph 2.C. to refer the user to the vendor information
and page 3 in the General Information section. Change “on” to upper case.
Added the metric conversion for “five inches”. Changed 5.0 inches
to 4.0 inches in paragraph 4.C.(2) to match the dimensions in
Figure 4. Changed the wording in paragraph 4.C.(3) for clarifica-
tion.

Part 2, Procedure 1, page 4 Added segments to paragraph 4.D.(6). General updates.

Part 2, Procedure 1, page 5 Modified paragraph 7.D.

Part 2, Procedure 1, pages 6 Updated Figures.

thru 14

Part 2, Procedure 2, page 1 Corrected paragraph 2.B.(2)(a) and (b) for “focused” and “unfo-
cused”.

Part 2, Procedure 2, page 2 Changed paragraph 2.C. to refer the user to the vendor information
in the General Information section. Added the WARNING for cad-
mium and corrected the wording of paragraph 3.A. with the NOTE
from Temporary Revision 32--1.

Part 2, Procedure 2, page 3 Added NOTE after paragraph 4.A.(5).

Part 2, Procedure 2, pages 6 Updated Figures.

thru 19
AMASZONAS S.A.

Highlights
CO: 8080

Page 2 of 4
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

Chapter/Section/Page No. Description of Change

(32--42--05 )
Eddy Current Inspection

Part 3, Procedure 1, page 1 Changed and added to the NOTE after paragraph 2.B.(1) regard-
ing the reference standard in different materials.

Part 3, Procedure 1, page 2 Changed paragraph 2.C. to refer the user to the vendor information
in the General Information section. Added the NOTE after para-
graph 3.B. General updates.

Part 3, Procedure 1, pages 3 General updates.

thru 5

Part 3, Procedure 1, pages 6 Updated Figures.

thru 24

(32--42--06 )
Magnetic Particle Inspection

Part 4, Procedure 1, page 1 Corrected the Specification ASTM--E1444 number from Tempo-
rary Revision 32--1. Changed paragraph 2.B. to refer the user to the
vendor information in the General Information section.

Part 4, Procedure 1, page 2 Added the NOTE after paragraph 5.A. General updates.

(32--42--07 )
Penetrant Inspection

Part 5, Procedure 1, page 1 Changed the Specification MIL--STD--6866 to ASTM E1417.

Changed “magnetic” to “ferromagnetic” in paragraph 1.B. Changed
paragraph 2.A. to refer the user to the vendor information in the
General Information section. Added paragraph 3.C. for removal of
paint.

Part 5, Procedure 1, page 2 Added the CAUTION for limits on crack repairs before paragraph
7.B.

AMASZONAS S.A.

Highlights
CO: 8080

Page 3 of 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

THIS PAGE
KEPT
BLANK

AMASZONAS S.A.

Highlights
CO: 8080

Page 4 of 4
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

RECORD OF REVISIONS

DATE DATE
REV ISSUE PUT INTO REV ISSUE PUT INTO
NO. DATE MANUAL BY NO. DATE MANUAL BY
1 Mar 01/05 Mar 01/05 ABSC

AMASZONAS S.A.

Record of Revisions
CO: 8080

Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

THIS PAGE

KEPT

BLANK

AMASZONAS S.A.
CO: 8080

Record of Revisions
Page 2
Mar 01/05
CO: 8080 AMASZONAS S.A. EMAIL: milton.ballesteros@amaszonas.com
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TEMPORARY REVISION NO. 32--2

TO: HOLDERS OF AP-763 NONDESTRUCTIVE TESTING MANUAL WITH PROCEDURES FOR

GENERAL INFORMATION (32--42--03), ULTRASONIC INSPECTION (32--42--04), EDDY
CURRENT INSPECTION (32--42--05), MAGNETIC PARTICLE INSPECTION (32--42--06),
PENETRANT INSPECTION (32--42--07) FOR ALL MEGGITT AIRCRAFT BRAKING SYSTEMS
WHEEL ASSEMBLIES AND BRAKE ASSEMBLIES
PURPOSE: This Temporary Revision is issued to add alternate ultrasonic inspection for
ferromagnetic and nonferromagnetic bolts.
FILING INSTRUCTIONS: This Temporary Revision supplements the contents of the last revision
of the Component Maintenance Manual specified and, if present, any previous Temporary Revision(s)
that are recorded in the RECORD OF TEMPORARY REVISIONS. Record applicable data on the
RECORD OF TEMPORARY REVISIONS sheet in the front of the manual, insert page 1 facing the
RECORD OF TEMPORARY REVISIONS, and insert the pages of this Temporary Revision as given
in the filing instruction on each page.
Retain this Temporary Revision and any previous Temporary Revision(s) pages, except when specified
differently in the filing instruction on each page, until the next manual revision incorporates the
information from this and all previous Temporary Revision(s) into the Component Maintenance Manual.
This Temporary Revision affects page(s) Part 1, General Information, page 2, (32--42--03), Part 4,
Procedure 1, page 1 (32--42--06).

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE BY DATE BY

REVISION NUMBER NUMBER DATE REMOVED
32--1 1 thru 8 Oct 10/95 ABSC Mar 01/05 ABSC
32--2 1 thru 3 May 16/11 MABS

AMASZONAS S.A.

Record of Temporary Revisions

CO: 8080

All Rights Reserved Page 1 of 3

Copyright E 2011
Meggitt Aircraft Braking Systems
May 16/11
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

REVISION NUMBER NUMBER DATE BY REMOVED BY
32--1 1 thru 8 Oct 10/95 ABSC Mar 01/05 ABSC

AMASZONAS S.A.

Record of Temporary Revisions

CO: 8080

Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

THIS PAGE

KEPT

BLANK

AMASZONAS S.A.

Record of Temporary Revisions

Page 2
CO: 8080

Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

SERVICE BULLETIN LIST

DATE DATE
SERVICE BULLETIN REV PUT INTO SERVICE BULLETIN REV PUT INTO
NUMBER NO. MANUAL NUMBER NO. MANUAL

AMASZONAS S.A.

Service Bulletin List

CO: 8080

Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

THIS PAGE

KEPT

BLANK

AMASZONAS S.A.

Service Bulletin List

Page 2
CO: 8080

Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title 1 Mar 01/05 Ultrasonic Inspection

Highlights 1 Mar 01/05 32--42--04
2 Mar 01/05 Table of Contents 1 Mar 01/05
3 Mar 01/05 2 Mar 01/05
4 Mar 01/05 Procedure 1 1 Mar 01/05
Record of 1 Mar 01/05 Wheel Subassembly 2 Mar 01/05
Revisions 2 Mar 01/05 3 Mar 01/05
4 Mar 01/05
Record of 1 Mar 01/05 5 Mar 01/05
Temporary Revisions 2 Mar 01/05 6 Mar 01/05
Service 1 Mar 01/05 7 Mar 01/05
Bulletin List 2 Mar 01/05 8 Mar 01/05
9 Mar 01/05
List of 1 Mar 01/05
10 Mar 01/05
Effective Pages 2 Mar 01/05
11 Mar 01/05
Table of 1 Mar 01/05 12 Mar 01/05
Contents 2 Mar 01/05
Procedure 2 1 Mar 01/05
Introduction 1 Mar 01/05 Wheel Tie Bolts 2 Mar 01/05
2 Mar 01/05 3 Mar 01/05
3 Mar 01/05 4 Mar 01/05
4 Mar 01/05 5 Mar 01/05
General Information 6 Mar 01/05
32--42--03 7 Mar 01/05
Table of Contents 1 Mar 01/05 8 Mar 01/05
2 Mar 01/05 9 Mar 01/05
10 Mar 01/05
General Information 1 Mar 01/05 11 Mar 01/05
2 Mar 01/05 12 Mar 01/05
3 Mar 01/05 13 Mar 01/05
4 Mar 01/05 14 Mar 01/05
5 Mar 01/05 15 Mar 01/05
6 Mar 01/05 16 Mar 01/05
17 Mar 01/05
18 Mar 01/05
19 Mar 01/05
20 Mar 01/05
AMASZONAS S.A.

List of Effective Pages

CO: 8080

Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

LIST OF EFFECTIVE PAGES (CONTINUED)

SUBJECT PAGE DATE SUBJECT PAGE DATE

Eddy Current Magnetic Particle

Inspection Inspection
32--42--05 32--42--06
Table of Contents 1 Mar 01/05 Table of Contents 1 Mar 01/05
2 Mar 01/05 2 Mar 01/05
Procedure 1 1 Mar 01/05 Procedure 1 1 Mar 01/05
Crack Inspection 2 Mar 01/05 Crack Inspection 2 Mar 01/05
3 Mar 01/05 3 Mar 01/05
4 Mar 01/05 4 Mar 01/05
5 Mar 01/05 5 Mar 01/05
6 Mar 01/05 6 Mar 01/05
7 Mar 01/05 Penetrant Inspection
8 Mar 01/05 32--42--07
9 Mar 01/05 Table of Contents 1 Mar 01/05
10 Mar 01/05 2 Mar 01/05
11 Mar 01/05
12 Mar 01/05 Procedure 1 1 Mar 01/05
13 Mar 01/05 Crack Inspection 2 Mar 01/05
14 Mar 01/05
15 Mar 01/05
16 Mar 01/05
17 Mar 01/05
18 Mar 01/05
19 Mar 01/05
20 Mar 01/05
21 Mar 01/05
22 Mar 01/05
23 Mar 01/05
24 Mar 01/05

AMASZONAS S.A.

List of Effective Pages

Page 2
CO: 8080

Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TABLE OF CONTENTS

SUBJECT PAGE

INTRODUCTION 1

PART 1 -- GENERAL INFORMATION (32--42--03) 1

1. General 1
2. Function 1
3. Manual Format 1
4. General Applications 1
5. Figures 3
6. Material/Equipment Vendor Addresses 4

PART 2 -- ULTRASONIC INSPECTION (32--42--04) 1

(PROCEDURE 1 -- WHEEL SUBASSEMBLY)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning of a Wheel Subassembly 2
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Subassembly 2
5. Ultrasonic Inspection Procedures for a Wheel Subassembly 4
6. Analysis of a Crack Indication in a Wheel Subassembly 4
7. Acceptance/Rejection Conditions for a Wheel Subassembly 5
8. Figures 6

PART 2 -- ULTRASONIC INSPECTION (32--42--04) 1

(PROCEDURE 2 -- WHEEL AND BRAKE TIE BOLTS)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning of a Wheel Tie Bolt 2
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Tie Bolt 2
5. Ultrasonic Inspection Procedures for a Wheel Tie Bolt 4
6. Analysis of a Crack Indication in a Wheel Tie Bolt 4
7. Acceptance/Rejection Conditions for a Wheel Tie Bolt 4
8. Figures 5

PART 3 -- EDDY CURRENT INSPECTION (32--42--05) 1

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
AMASZONAS S.A.

3. Preparation and Cleaning 2

4. Equipment Adjustment for Eddy Current Inspection 3
5. Eddy Current Inspection Procedures 3
6. Analysis of Crack Indications 4
7. Acceptance/Rejection Conditions for Component with Crack Indications 5
8. Figures 6

Table of Contents
CO: 8080

Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TABLE OF CONTENTS (CONTINUED)

SUBJECT PAGE

PART 4 -- MAGNETIC PARTICLE INSPECTION (32--42--06) 1

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning 1
4. Equipment Adjustment for Magnetic Particle Inspection 1
5. Magnetic Particle Inspection Procedures 2
6. Analysis of Crack Indications 2
7. Acceptance/Rejection Conditions for Component with Crack Indications 3
8. Figures 4

PART 5 -- PENETRANT INSPECTION (32--42--07) 1

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning 1
4. Equipment Adjustment 1
5. Penetrant Inspection Procedures 1
6. Analysis of a Crack Indication 1
7. Acceptance/Rejection Conditions for a Component with Crack Indications 2
8. Figures 2

AMASZONAS S.A.

Table of Contents
CO: 8080

Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

INTRODUCTION

This manual is written according to Air Transport Association Specification No. 100 for the overhaul
and/or maintenance of the Aircraft Braking Systems Corporation (ABSC*) assembly(ies) included.
THIS MANUAL IS APPLICABLE ONLY FOR THE OVERHAUL OF THE INCLUDED ABSC
PRODUCT(S) WITH ONLY ABSC PRODUCED OR APPROVED PARTS AND APPROVED
PROCEDURES. THE USE OF UNAPPROVED PARTS OR THE OMISSION OR ALTERATION OF
APPROVED PROCEDURES NEGATES THE VALIDITY OF THIS MANUAL. The use of unapproved
nondestructive inspection procedures or omissions of recommended nondestructive inspection
procedures relieves ABSC of its product liability obligations as to ABSC products subject to such
testing. All specific repair limits must be obeyed. Any alternative procedures, limits, or materials must
not decrease the reliability of the nondestructive test on the assembly.
The person or facility that uses unapproved procedures or omits recommended procedures to do an
overhaul or maintenance to ABSC products may not rely on this manual, must do so at their own risk
and must assume product liability. All torque values and specific limits apply only to ABSC approved
parts/products and must be obeyed. Any alternative procedures, limits, or materials (if consented to
in writing by ABSC) must not decrease the performance of the assembly.
All dimensions and other values are in English units followed by the SI (International System) units
in parentheses. Illustration dimensions are in inches with millimeter conversions in parentheses
unless specified. Dimensions of standard tools or parts are in English units where there are no
equivalent metric tools or parts. Illustrations are for reference only and are not to scale.
Aircraft Braking Systems Corporation represents that the information contained in this manual is
valid only for use with ABSC approved parts and procedures and was current at the time of publication
and verified by comparison to engineering documentation.
The user should make sure that this is the most recent publication before overhaul or maintenance
is performed. A dealer, distributor or Customer Support Department can tell the user if this is the most
recent manual. Refer to the attached sheets for the nearest Customer Support location. You may
make direct inquires to the Distributor Representative--Marketing, Aircraft Braking Systems
Corporation, 1204 Massillon Road, Akron, Ohio 44306--4186 or to the Technical Publication
Department on e--mail at techpubs@aircraftbraking.com.
If this manual, the component maintenance manual, and the aircraft maintenance manual do not agree
on the aircraft interface connections, use the aircraft maintenance manual. This manual may give
component functions that may or may not be used when installed on the aircraft.
NOTICE
AIRCRAFT BRAKING SYSTEMS CORPORATION (ABSC) ASSUMES NO
CONTRACTUAL, WARRANTY, PRODUCT LIABILITY OR OTHER OBLIGATION
FOR ANY SUBSTITUTION OF OR ALTERATION TO ANY PART CONTAINED IN
AMASZONAS S.A.

ANY ABSC WHEEL OR BRAKE ASSEMBLY INCLUDING ACCESSORIES NOT

SPECIFICALLY AUTHORIZED BY ABSC OR FOR ANY OVERHAUL OR
MAINTENANCE NOT PERFORMED IN ACCORDANCE WITH ABSC
APPROVED PROCEDURES.

* ABSC is the registered trademark of Aircraft Braking Systems Corporation

Introduction
Page 1
CO: 8080

Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

DATA RIGHTS
The cost for this manual includes printing and shipping costs only and does not
include purchase of the data or design. It does not give the purchaser any rights
or patent to print or make parts from this data.

SAFETY SUMMARY

Obey all manufacturer’s Warnings and Cautions for all materials specified in this
manual. In this manual, Warnings and Cautions come before the procedure to
which they apply. Failure to obey a Warning may cause personal injury. Failure
to obey a Caution may cause damage to equipment or components. Wear
protective clothing approved for the materials and tools being used.

ON--CONDITION MAINTENANCE

Each operator must schedule maintenance based on the condition of his

equipment. Aircraft Braking Systems Corporation recommends that on--condition
maintenance be performed.

ATA Common Support Data Dictionary (CSDD) defines on--condition maintenance

as follows:

A primary maintenance process having repetitive inspections or tests to determine

the condition of units, systems or portions of structure with regard to continued
serviceability (corrective action is taken when required by item condition).

AMASZONAS S.A.

Introduction
CO: 8080

Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

AIRCRAFT BRAKING SYSTEMS CORPORATION

CUSTOMER SUPPORT LOCATIONS

California, Los Angeles Oklahoma, Tulsa

Aircraft Braking Systems Corporation Aircraft Braking Systems Corporation
9552 Caithness Drive 5103 South Sheridan Road
Huntington Beach, California 92646 Suite 140
Tulsa, Oklahoma 74145--7627
Phone: 714--962--6438
Fax: 714--962--6978 Phone: 918--481--5516
Fax: 918--497--1221
England, London
Ohio, Akron (Home Office)
Aircraft Braking Systems Europe, Ltd
683--685 Stirling Road Aircraft Braking Systems Corporation
Slough, Berkshire, England SL1 4ST Field Sales and Service Headquarters
1204 Massillon Road
Phone: 44--1--753--696--006 Akron, Ohio 44306--4186
Telex: 846695--ABSEL--G
Fax: 44--1--753--696--012 Phone: 330--796--4400
Fax: 330--796--9805
France, Toulouse
Customer Service Department
Aircraft Braking Systems Europe, Ltd Aircraft Braking Systems Corporation
Centre D’Affaires Partner 1204 Massillon Road
2 bis rue Marcel Doret Manufacturing Maintenance Facility
31700 Blagnac, France No. 33121
Akron, Ohio 44306--4186
Phone: 33--5-- 61--30--9898
33--5--61--30--9862
Telex: 532463F--PARTNER
Fax: 33--5--61--30--9867 or 0045

Kentucky, Hebron
Aircraft Braking Systems Corporation
P.O. Box 150
Hebron, KY 41048

Phone: 859--689--1800
Fax: 859--689--7291
AMASZONAS S.A.

Introduction
Page 3
CO: 8080

Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

THIS PAGE
KEPT
BLANK

AMASZONAS S.A.

Introduction
CO: 8080

Page 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

TABLE OF CONTENTS

SUBJECT PAGE

PART 1 -- GENERAL INFORMATION (32--42--03)

1. General 1
2. Function 1
3. Manual Format 1
4. General Applications 1
5. Figures 3
6. Material/Equipment Vendor Addresses 4

AMASZONAS S.A.

Part 1
Table of Contents
CO: 8080

Page 1
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

TABLE OF FIGURES

FIGURE PAGE

PART 1 -- GENERAL INFORMATION (32--42--03)

Figure 1 NDT Areas for Wheel Subassemblies 3

AMASZONAS S.A.

Part 1
Table of Contents
CO: 8080

Page 2
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

PART 1 -- GENERAL INFORMATION

1. General
NOTE: It is recommended the procedures given in this manual be done by persons approved
by accepted industry standards such as ATA--105, NAS--410, ASNT--SNT--TC1A or
equivalent.
A. This manual is applicable to all Aircraft Braking Systems Corporation (ABSC) Component
Maintenance Manuals for wheel and brake assemblies where nondestructive testing proce-
dures are used but no instructions are given. When instructions are given, the procedures
contained in this manual are alternate equivalent procedures for achieving the results de-
sired in the specific Component Maintenance Manual.
B. This manual gives specific procedures for the inspection of the components of wheel and
brake assemblies.
2. Function
A. The function of this manual is to give inspection procedures that permit the components of
the wheel assemblies and the brake assemblies to be used again.
B. The inspection procedures given can find fatigue cracks on in--service components before
failures occur.
3. Manual Format
A. The NDT procedures given in this manual are divided into parts. Each part is for a different
nondestructive test.
PART 2: Ultrasonic Inspection
PART 3: Eddy Current Inspection
PART 4: Magnetic Particle Inspection
PART 5: Penetrant Inspection
4. General Applications
A. The inspection procedures given can be used for ABSC wheel assemblies as follows:
(1) Ultrasonic Inspection (PART 2)
(a) An ultrasonic inspection can be done as an alternate procedure for the eddy cur-
rent inspection on the bead seat and the adjacent tube well areas. See PART 2,
Procedure 1.
(b) An ultrasonic inspection can be done on the ferromagnetic and non ferromagnet-
AMASZONAS S.A.

ic tie bolts as an alternative for the magnetic particle inspection or the fluorescent
penetrant inspection. See PART 2, Procedure 2.
(2) Eddy Current Inspection (PART 3)
(a) An eddy current inspection must be done on the bead seat and the adjacent tube
well areas. See Figure 1.

Part 1
CO: 8080

32--42--03
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

(b) An eddy current inspection must be done on all other areas where abrasion can
smear the metal which can cause the penetrant inspection not to find cracks. See
Figure 1.
(c) An eddy current inspection can be done on ferromagnetic and nonmagnetic
wheel and tie bolts as an alternative for the magnetic particle inspection or the
penetrant inspection. See PART 4, Procedure 1.
(3) Magnetic Particle Inspection (PART 4)
(a) A magnetic particle inspection can be used to find cracks in all ferromagnetic tie
bolts. The magnetic particle inspection must be done as told in ASTM--E1444 or
an equivalent magnetic particle process specification.
(4) Penetrant Inspection (PART 5)
(a) A penetrant inspection can be used to find cracks in all non--ferromagnetic tie
bolts. The penetrant inspection must be done as told in ASTM E1417 or equiva-
lent fluorescent penetrant inspection process specification. See Figure 1.
NOTE: ABSC only recommends the use of fluorescent penetrant inspections.
Other visible penetrant inspections must not be used on ABSC com-
ponents.
(b) A penetrant inspection can be used to find cracks in all wheel subassemblies in
the areas where it is not necessary to do an eddy current inspection. See
Figure 1.
B. The inspection procedures given can be used for ABSC brake assemblies as follows:
(1) Ultrasonic Inspection
(a) Not applicable.
(2) Eddy Current Inspection
(a) An eddy current inspection must be done on all areas of the nonmagnetic parts
(brake housings) shown in the applicable Component Maintenance Manual.
(3) Magnetic Particle Inspection
(a) A magnetic particle inspection must be used to find cracks in all ferromagnetic
brake components that must have an inspection. The magnetic particle inspec-
tion must be done as told in ASTM--E1444 or an equivalent magnetic particle pro-
cess specification.
(4) Penetrant Inspection
(a) A penetrant inspection can be used to find cracks in all non--ferromagnetic brake
AMASZONAS S.A.

components that must have an inspection. The penetrant inspection must be

done as told in ASTM E1417 or equivalent fluorescent penetrant inspection pro-
cess specification.
NOTE: ABSC only recommends the use of fluorescent penetrant inspections.
Other dye penetrant inspections must not be used on ABSC compo-
nents.

Part 1
CO: 8080

Page 2
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TEMPORARY REVISION NO. 32--2

FILING INSTRUCTIONS: Insert facing Part 1, General Information, page 2 (32--42--03).

DESCRIPTION: Revised to MABS. Revised paragraph 4.B.(1)(a) for Ultrasonic Inspection. Added
paragraph 4.B.(2) (b) for Eddy Current Inspection.

B. The inspection procedures given can be used for MABS brake assemblies as follows:

(1) Ultrasonic Inspection

(a) An ultrasonic inspection can be done on the ferromagnetic and non ferromagnetic
bolts as an alternative for the magnetic particle inspection or the florescent
penetrant inspection. See PART 2, Procedure 2.

(2) Eddy Current Inspection

(a) An eddy current inspection must be done on all areas of the nonmagnetic parts
(brake housings) shown in the applicable Component Maintenance Manual.

(b) An eddy current inspection can be done on the ferromagnetic and non
ferromagnetic bolts as an alternative for the magnetic particle inspection or the
penetrant inspection. See PART 4, Procedure 1.

AMASZONAS S.A.
CO: 8080

Page 2 of 3
May 16/11
CO: 8080 AMASZONAS S.A. EMAIL: milton.ballesteros@amaszonas.com
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

5. Figures

1 2

0.25 (6,35) BEYOND TANGENT POINT

NOTES:

1 DO AN EDDY CURRENT INSPECTION ON THIS AREA

2 ALTERNATIVELY, DO AN ULTRASONIC INSPECTION OF THE AREA

3 DO AN EDDY CURRENT INSPECTION OF THESE AREAS IF ABRASION HAS

SMEARED THE METAL.
AMASZONAS S.A.

4. DO A PENETRANT INSPECTION TO EXAMINE ALL OTHER AREAS OF THE

WHEEL SUBASSEMBLY.

NDT Areas for Wheel Subassemblies

Figure 1

Part 1
CO: 8080

32--42--03
Page 3
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

6. Material/Equipment Vendor Addresses

A. Nondestructive Testing Materials and Tooling vendor information:

Equipment/Material Vendor/Address
Liquid Couplant: Oil, Exosen or equivalent Commercially available
Reference Standard Uniwest
Eddy Current Instruments 330 West Clark Street
Eddy Current Test Coils Pasco, WA 99301
Ph: (509) 544--0720
Fax: (509) 544--0868
www.uniwest.com
Ultrasonic Bolt Tank Rohmann, Incorporated
Reference Standard 114 Perimeter Road
Ultrasonic Search Unit Nashua, NH 03063
Eddy Current Instruments Ph: (603) 595--4220
Eddy Current Test Coils Fax: (603) 595--4221
www.rohmann.com
Reference Standards NDT Engineering Corp.
Ultrasonic Transducers 19620 Russell Road
Eddy Current Test Coils Kent, WA 98032
Ph: (253) 872--3565
Fax: (253) 872--0857
www.rd--tech.com
Reference Standard EC--NDT, LLC
Eddy Current Test Coils 1020 South 344th Street
Suite 214
Federal Way, WA 98003
Ph: (253) 815--0797
(877) 565--0797
Fax: (253) 815--0827
www.ec--ndt.com
Ultrasonic Flaw Detector Customer Support
Reference Standard GE Inspection Technologies, LP
Search Unit 50 Industrial Park Road
Eddy Current Instruments Lewistown, PA 17044
Eddy Current Test Coils Ph: (866) 243--2638
Wheel Test Systems Ph: (717) 242--0327
Fax: (717) 242--2606
www.geinspectiontechnologies.com
AMASZONAS S.A.

NOTE: Equivalent replacements can be used for the items given.

Part 1
CO: 8080

Page 4
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

Equipment/Material Vendor/Address
Ultrasonic Flaw Detector Staveley NDT Technologies
Reference Standard 421 North Quay Street
Search Unit Kennewick, WA 99336
Eddy Current Instruments Ph: (509) 736--2751
Eddy Current Test Coils Fax: (509) 735--4672
www.staveleyndt.com
Ultrasonic Flaw Detector SONATEST, Incorporated
Reference Standard 4734 Research Drive
Search Unit San Antonio, TX 78240
Ph: (210)69 7--0335
Fax: (210) 697--0767
www.sonatest--plc.com
Reference Standard VM Products, Incorporated
Search Unit P.O. Box 44926
Eddy Current Test Coils Tacoma, WA 99444--0926
Ph: (253) 841--2939
Fax: (253) 841--3016
www.vmproducts.net
Reference Standard Versatile Products
Eddy Current Test Coils 117 Eva Lane
P.O. Box 567
Higgins Lake, MI 48627
Ph: (517) 821--7424
Wheel Test Systems ANDEC Manufacturing, Ltd.
Eddy Current Test Coils 124 Skyway Avenue
Reference Standard Toronto, Canada M9W 4Y9
Ultrasonic Test Systems Ph: (416) 213--8000
Fax: (416) 213--8004
www.andec.on.ca
Penetrant Inspection Materials Magnaflux
3264 W Lake Ave
Glenview, IL 60026
Ph: (847) 657--5300
Fax: (847) 657--5338
www.magnaflux.com
Penetrant Inspection Materials Sherwin Incorporated
Penetrant Inspection Equipment 5530 Borwick Avenue
South Gate, CA 90280
Ph: (562) 861--6324
AMASZONAS S.A.

Fax: (562) 923--8370

www.sherwininc.com

NOTE: Equivalent replacements can be used for the items given.

Part 1
CO: 8080

32--42--03
Page 5
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
GENERAL INFORMATION

Equipment/Material Vendor/Address
Penetrant Inspection Materials Chemetall Oakite Incorporated
50 Valley Road
Berkeley Heights, NJ 07922
Ph: (908) 464--6900
www.
oakite.com/aerospace/airframe--oem.cfm
Penetrant Inspection Materials Ely Chemical Company Limited
Magnetic Particle Inspection Materials Lisle Lane
Ely
Cambridgeshire, UK
CB7 4AS
Ph: 44 (0) 1353 665 881
Fax: 44 (0) 1353 664 623
USA Ph: (574) 251--9152
USA Fax: (574) 251--9157
www.elychemical.com
email: sales.dept@elychemical.co.uk
email: sales@elychemical.us
Magnetic Inspection Equipment Gould--Bass Company Incorporated
Magnetic Particle Inspection Equipment 1431 West Second Street
Pomona, CA 91766
Ph: (909) 623--6793
Fax: (909)62 9--1467
www.gould--bass.com
Magnetic Inspection Equipment Magwerks
Magnetic Particle Inspection Supplies 4024 W. 10th Street
Indianapolis, IN 46222
Ph: (317) 241--8011
Fax: (317) 241--8015
www.magwerks.com

NOTE: Equivalent replacements can be used for the items given.

B. Additional information and available vendors of equipment and materials are available on
the World Wide Web for the American Society for Nondestructive Testing, Inc. at
http://www.asnt.org. Consult the NDT buyers guide to locate vendors that are local to the
needs of your NDT testing.
AMASZONAS S.A.

Part 1
CO: 8080

Page 6
32--42--03 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

TABLE OF CONTENTS

SUBJECT PAGE

PART 2 -- ULTRASONIC INSPECTION (32--42--04)

(PROCEDURE 1 -- WHEEL SUBASSEMBLY)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning of a Wheel Subassembly 2
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Subassembly 2
5. Ultrasonic Inspection Procedures for a Wheel Subassembly 4
6. Analysis of a Crack Indication in a Wheel Subassembly 4
7. Acceptance/Rejection Conditions for a Wheel Subassembly 5
8. Figures 6

PART 2 -- ULTRASONIC INSPECTION (32--42--04)

(PROCEDURE 2 -- WHEEL AND BRAKE TIE BOLTS)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning of a Wheel Tie Bolt 2
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Tie Bolt 2
5. Ultrasonic Inspection Procedures for a Wheel Tie Bolt 4
6. Analysis of a Crack Indication in a Wheel Tie Bolt 4
7. Acceptance/Rejection Conditions for a Wheel Tie Bolt 4
8. Figures 5

AMASZONAS S.A.

Part 2
Table of Contents
CO: 8080

Page 1
32--42--04 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

TABLE OF FIGURES

FIGURE PAGE

PART 2 -- ULTRASONIC INSPECTION (32--42--04)

(PROCEDURE 1 -- WHEEL SUBASSEMBLY)
Figure 1 Typical Ultrasonic Reference Standard (Wheel) . . . . . . . . . . . . . . . . . . . 6
Figure 2 Surface Wave Propagation in the Ultrasonic Reference Standard . . . . 7
Figure 3 Ultrasonic Surface Wave Reference Standard . . . . . . . . . . . . . . . . . . . . 8
Figure 4 Distance Calibration of the Ultrasonic Inspection Instrument . . . . . . . . 9
Figure 5 Location of the Primary Reference Level . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6 CRT with Three Distance Amplitude Curve Points . . . . . . . . . . . . . . . . . 10
Figure 7 Distance Amplitude Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 8 50% and 100% Distance Amplitude Curves . . . . . . . . . . . . . . . . . . . . . . 11
Figure 9 Ultrasonic Inspection of the Wheel Bead Seat . . . . . . . . . . . . . . . . . . . . 12

PART 2 -- ULTRASONIC INSPECTION (32--42--04)

(PROCEDURE 2 -- WHEEL TIE BOLTS)
Figure 1 Important Inspection Areas of Wheel Tie Bolts . . . . . . . . . . . . . . . . . . . . 5
Figure 2 Equipment Used for the Ultrasonic Inspection of Wheel Tie Bolts . . . . 5
Figure 3 Location of Reference Notch in the Bolt Reference Standard for
Head to Shank Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 4 Bolt Proof Standard for Thread Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Example of a Holding Fixture for Making Bolt Ends Flat and
Perpendicular to the Longitudinal Axis of a Bolt . . . . . . . . . . . . . . . . . . . 7
Figure 6 Water Path Between the Transducer and the Bolt End . . . . . . . . . . . . . 8
Figure 7 Indication Pattern from an Acceptable Thread Area . . . . . . . . . . . . . . . . 9
Figure 8 Indication from a Notch 3 to 4 Threads from the Bolt Shank . . . . . . . . 10
Figure 9 Indication from a Notch in the Incomplete Thread Area . . . . . . . . . . . . . 10
Figure 10 Water Path Adjustment for the Head--to--Shank Ultrasonic Inspection 12
Figure 11 Typical CRT Display with an Indication from a Mid--Shank Notch . . . . 13
Figure 12 Indication from a Head--To-- Shank Notch . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13 Ultrasonic Indication Pattern from an Acceptable Thread Area
of a Wheel Tie Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 14 ‘‘Positive” Fatigue Crack Indication in the Thread Area
of a Wheel Tie Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 15 ‘‘Negative” Fatigue Crack Indication in the Thread Area
AMASZONAS S.A.

of a Wheel Tie Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Part 2
Table of Contents
CO: 8080

Page 2
32--42--04 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

PART 2 -- ULTRASONIC INSPECTION

(PROCEDURE 1 -- WHEEL SUBASSEMBLY)

1. Effectivity

A. An ultrasonic inspection can be done as an alternate procedure on all wheel assemblies

as told in the applicable Component Maintenance Manual and as follows:

(1) An ultrasonic inspection can be done as an alternate procedure for the eddy current
inspection on the bead seat and the adjacent tube well areas.

B. It is not necessary to do an ultrasonic inspection of the brake assembly components unless

the applicable Component Maintenance Manual says an ultrasonic must be done.

2. Tooling and Equipment

A. Contact surface (Rayleigh) wave techniques are used for the bead seat inspection.

B. Ultrasonic Test Equipment, Materials and Tooling parameters:

(1) Ultrasonic Flaw Detector -- a pulse echo ultrasonic flaw detector is recommended. The
flaw detector must have a minimum frequency range between 2.0 and 10.0 MHz.

(2) Search Unit (for inspection of the wheel subassembly bead seat only) -- maximum 0.50
inch (12,7 mm) diameter transducer attached to a Lucite (or equivalent) wedge to give
a refracted beam angle of 90° in the component that must be examined. The nominal
frequency of the search unit must be 2.25 MHz.

NOTE: Operate the search unit at its nominal frequency.

(3) Liquid Couplant -- oil, Exosen or equivalent material. A liquid couplant must be used
to conduct the ultrasonic waves between the transducer and the component that is
examined.

(4) Wheel Reference Standard -- see Figure 1. The reference notch must have the dimen-
sions that follow:

Forged Aluminum Components

length: 0.070 + 0.010 inch (1,78 + 0,25 mm)

width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
depth: 0.030 + 0.005 inch (0,76 + 0,13 mm)

NOTE: The wheel reference standard can be the same as the reference standard
used for the eddy current inspection.
AMASZONAS S.A.

Cast Aluminum and Magnesium Components

length: 0.120 + 0.012 inch (3,05 + 0,30 mm)

width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
depth: 0.030 + 0.003 inch (0,76 + 0,08 mm)

Part 2
Procedure 1
CO: 8080

32--42--04
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

(a) The reference standard must be made from a material similar in composition and
geometry to the wheel subassembly that must be examined. When ultrasonic in-
spection is used to examine the wheel bead seat area for indications of fatigue
cracks, the surface (Rayleigh) wave method is recommended. This method of
inspection is very sensitive to surface and near surface discontinuities positioned
with their major plane perpendicular to the ultrasonic beam. Figure 2 shows a
pictorial view of the surface wave propagation in an ultrasonic reference stan-
dard.

(b) If paint will be on the wheel subassembly during ultrasonic inspection, the refer-
ence standard must have paint applied to it in the area where the sound beam
will be applied during calibration as shown in Figure 3. The paint on the reference
standard must be approximately the same thickness as the paint on the wheel
subassembly to be examined.

C. Ultrasonic test equipment, materials and tooling -- See vendor information in the General
Section of this manual.

3. Preparation and Cleaning of a Wheel Subassembly

A. Disassemble the wheel assembly as told in the DISASSEMBLY section of the applicable
Component Maintenance Manual.
B. Clean the bead seat and tubewell areas that must have an inspection done on them as told
in the CLEANING section of the applicable Component Maintenance Manual.
(1) Remove all loose paint, tire rubber, chipped paint and other unwanted material from
the wheel subassembly in the area that must be examined. It is not necessary to re-
move all of the paint from the wheel subassembly when an ultrasonic inspection is
done.
NOTE: Chipped or blistered paint will cause ultrasonic indications similar to the in-
dications made by cracks in the wheel material. It is necessary to make a
careful analysis of all of these areas that show crack indications.
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Subassembly
A. Turn ultrasonic flaw detector ON and let it come to steady state.

B. Connect the search unit and the connecting cable to the flaw detector.

C. Adjust the ultrasonic flaw detector sweep range and sweep delay controls to make the
sweep line (trace) show a five inch (127 mm) sound path as follows:

(1) Choose the calibration notch on the calibration block in the area that shows the same
AMASZONAS S.A.

surface condition of the area of the wheel component that will be examined. If the area
of the wheel is painted, use the notch under the paint. See Figure 3.

(2) Identify the reference block in equal increments (for example: 1.00 inch (25,4 mm) in-
crements) that start from the reference notch and extend up to 4.00 inches (101,6 mm)
as shown in Figure 4.

Part 2
Procedure 1
CO: 8080

32--42--04
Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

(3) Put the search unit 2.00 inches (50,8 mm) from the reference notch (identified by a
pencil mark) with the sound beam pointed at the reference notch.

NOTE: Put the sound beam exit point of the search unit directly over the identifica-
tion on the reference standard. See Figure 4.

It is not necessary to use the 2.00 inch (50,8 mm) and the 4.00 inch
(101,6 mm) identifications for the distance calibration. Choose any two
identifications on the reference standard and adjust the CRT sweep line so
the maximum usable distance on the CRT display corresponds to an
approximate distance of 5.00 inches (127,0 mm) from the reference notch
to the search unit.

(4) Adjust the sweep controls until the indication on the CRT sweep line is at the ‘‘4” posi-
tion on the screen. See Figure 4.

(5) Put the search unit over the fourth identification (4.00 inch (101,6 mm) identification)
with the sound beam pointed at the reference notch.

(6) Adjust the sweep controls until the indication on the CRT sweep line is at the ‘‘8” posi-
tion on the screen. See Figure 4.

(7) Repeat steps (3) through (6) until no sweep control adjustments are necessary for the
signals to appear at the ‘‘4” and ‘‘8” positions on the screen.

D. Adjust the sensitivity of the ultrasonic test equipment as follows:

(1) Choose the calibration notch on the calibration block in the area that shows the same
surface condition of the area of the wheel component that will be examined. If the area
is painted, use the notch under the paint.

(2) Put the search unit at the first identification [1.00 inch (25,4 mm) identification] away
from the reference notch on the calibration block.

(3) Adjust the instrument gain (sensitivity) control so the signal from the reference notch
is between 75 and 90 percent of the full screen height (FSH).

(4) Identify the peak amplitude of this signal on the screen as shown in Figure 5. This is
the first point of the distance amplitude curve (DAC). Make a note (save) of this gain
setting because this is the Primary Reference Level for the test. AMASZONAS S.A.

NOTE: It is acceptable to use an electronic DAC as an alternative to the manually

made DAC.

(5) Do not change the instrument controls. Position the transducer at two different posi-
tions no more than 5.00 inches (127,0 mm) from the reference notch on the calibration
block. See Figure 6. Identify the maximum amplitude from each of these indications.

Part 2
Procedure 1
CO: 8080

32--42--04
Page 3
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

(6) Connect the three points with straight line segments to make a distance amplitude
curve (DAC) as shown in Figure 7.

(7) Draw a 50% DAC on the screen at 1/2 the height of the 100% DAC as shown in
Figure 8. The lower DAC (50% DAC) will be the acceptance level when the sensitivity
is set at the Primary Reference Level.

5. Ultrasonic Inspection Procedures for a Wheel Subassembly

A. After the ultrasonic equipment has been calibrated as told in paragraph 4., Equipment Ad-
justment, use the sensitivity control to double the test sensitivity. For instruments that use
calibrated gain controls, increase the gain by 6 dB to double the test sensitivity.

B. Apply the couplant to the wheel in a narrow band. When the search unit is placed on the
wheel and the sound beam is directed toward the bead seat/rim area, no couplant is per-
mitted in front of the search unit. See Figure 9 for the position of the search unit in relation
to the wheel bead seat.

CAUTION: ♦ DO NOT GET THE COUPLANT AHEAD OF THE SEARCH UNIT IN THE
DIRECTION OF THE SOUND BEAM PROPAGATIONS. COUPLANT WILL
DECREASE THE INTENSITY OF THE SOUND BEAM AND/OR CAUSE FALSE
INDICATIONS.

C. Make a scan of the wheel segment in two continuous paths that overlap as shown in
Figure 9. Keep the distance of each scan an equal distance from the bead seat along the
full path of the scan. Do not let the distance from the scan to the bead seat be greater than
the maximum distance on the DAC.

6. Analysis of a Crack Indication in a Wheel Subassembly

A. Set the sensitivity level to the Primary Reference Level noted in paragraph 4.D.(4) and
make a scan of an area that shows an indication to find the location of the crack indication.

B. An indication which is more than the 50% DAC (see paragraph 4.D.(7)) must be examined
to make a decision whether or not it is caused by a fatigue crack.

(1) Make sure the indication is not false (couplant in front of the search unit, bubbled paint,
or other paint damage). Remove the paint in the area of the crack indication if neces-
sary.

(2) Make sure the indication is not an intentional indication (fusible plug hole or other hole
or other change in the surface contour). AMASZONAS S.A.

(3) If the indication is not a false indication or an intentional indication, identify the indica-
tion on the wheel subassembly.

Part 2
Procedure 1
CO: 8080

32--42--04
Page 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

7. Acceptance/Rejection Conditions for a Wheel Subassembly

A. Remove a wheel subassembly from service if it has crack indications more than 50% of the
DAC at the Primary Reference Level.

B. If an ultrasonic inspection shows crack indications in areas of the wheel subassembly that
have paint, remove the paint from the wheel subassembly as told in the CLEANING section
of the applicable Component Maintenance Manual. After the paint is removed, do an eddy
current inspection or an ultrasonic inspection of the wheel subassembly again.

C. Repair areas that have crack indications to the limits given in the REPAIR section of the
applicable Component Maintenance Manual.

D. Do a second eddy current or ultrasonic inspection of the wheel subassembly after the areas
with crack indications are repaired. If the wheel subassembly still has crack indications,
remove wheel subassembly from service.

AMASZONAS S.A.

Part 2
Procedure 1
CO: 8080

32--42--04
Page 5
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

8. Figures

REFERENCE
NOTCHES

2.625 (66,7)
3.250 (82,6)

CALIBRATION STANDARD

NOTCH DIMENSIONS (2 PLACES)

LENGTH WIDTH DEPTH

0.070 +0.010 0.006 +0.004 0.030 +0.005

(1,78 +0,25) (0,15 +0,10) (0,76 +0,13) AMASZONAS S.A.

Typical Ultrasonic Reference Standard (Wheel)

Figure 1
Part 2
Procedure 1
CO: 8080

32--42--04
Page 6
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

SEARCH UNIT

AMASZONAS S.A.

Surface Wave Propagation in the Ultrasonic Reference Standard

Figure 2
Part 2
Procedure 1
CO: 8080

32--42--04
Page 7
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

FLANGE FACE

REFERENCE
NOTCHES

PAINTED AREA

NOTES:

1. A PAINTED AREA CONTAINING A REFERENCE NOTCH IS ONLY REQUIRED

WHEN THE WHEEL IS PAINTED
AMASZONAS S.A.

Ultrasonic Surface Wave Reference Standard

Figure 3
Part 2
Procedure 1
CO: 8080

32--42--04
Page 8
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

REFERENCE SEARCH UNIT

NOTCH
SOUND BEAM EXIT POINT

PENCIL MARK AT EACH

MEASURED INCH

2.00
(50,8)
4.00
(101,6)

INITIAL PULSE REF NOTCH AT 2.00 (50,8)

REF NOTCH AT 4.00 (101,6)

100

80
PERCENT

60

40

20

0
AMASZONAS S.A.

0 2 4 6 8 10

1” 2” 3” 4”

Distance Calibration of the Ultrasonic Inspection Instrument

Figure 4
Part 2
Procedure 1
CO: 8080

32--42--04
Page 9
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

REF NOTCH INDICATION AT

INITIAL PULSE
1.00 (25,4) DISTANCE

100

80
PERCENT

60

40

20

0
0 2 4 6 8 10

1”

Location of the Primary Reference Level

Figure 5

REF NOTCH RESPONSE AT

PRIMARY REF LEVEL APPROXIMATELY 2.375 (60,33)
INITIAL PULSE
REF NOTCH RESPONSE AT
APPROXIMATELY 4.00 (101,6)
100

80
PERCENT

60

40

20
AMASZONAS S.A.

0
0 2 4 6 8 10

CRT with Three Distance Amplitude Curve Points

Figure 6

Part 2
Procedure 1
CO: 8080

32--42--04
Page 10
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

INITIAL PULSE DISTANCE AMPLITUDE

CURVE (DAC)

100

PERCENT 80

60

40

20

0
0 2 4 6 8 10

Distance Amplitude Curve

Figure 7

INITIAL PULSE DISTANCE AMPLITUDE

CURVE (DAC)

100

80
PERCENT

60

40

20 100%

50%
AMASZONAS S.A.

0
0 2 4 6 8 10

50% and 100% Distance Amplitude Curves

Figure 8

Part 2
Procedure 1
CO: 8080

32--42--04
Page 11
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

2 3
1

3
2
1

ULTRASONIC WAVE PROP

TRANSDUCER MOVEMENT

TRANSDUCER SCAN PATH AMASZONAS S.A.

1. TRANSDUCER MAXIMUM SCAN RATE 6 IN/SEC IN CIRCUMFERENTIAL DIRECTION

AROUND WHEEL
2. TWO CIRCUMFERENTIAL SCAN PATH BANDS WITH A MINIMUM 0.50 INCH (12,7 MM)
OVERLAP
3 AREA OF COVERAGE TYPICAL BOTH HALVES

Ultrasonic Inspection of the Wheel Bead Seat Part 2

Figure 9 Procedure 1
CO: 8080

32--42--04
Page 12
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

PART 2 -- ULTRASONIC INSPECTION

(PROCEDURE 2 -- WHEEL TIE BOLTS)

1. Effectivity
A. An ultrasonic inspection can be done as an alternate procedure on all wheel assemblies
as told in the applicable Component Maintenance Manual and as follows:
(1) An ultrasonic inspection can be done on the ferromagnetic and nonferromagnetic
wheel tie bolts as an alternative for the magnetic particle inspection or the penetrant
inspection. The important areas of the tie bolts that must be examined are shown in
Figure 1.
B. It is not necessary to do an ultrasonic inspection of the brake assembly components.
2. Tooling and Equipment
A. Ultrasonic immersion techniques with a special fixture are used for the inspection of wheel
tie bolts for fatigue cracks.
B. Ultrasonic Test Equipment, Materials and Tooling parameters (See Figure 2):
(1) Ultrasonic Flaw Detector -- a pulse echo or ultrasonic flaw detector is recommended.
The flaw detector must operate in a frequency range between 2.0 and 10.0 MHz.
(2) Ultrasonic Immersion Transducers (for inspection of wheel tie bolts only)
(a) Focused Transducer -- 0.250 inch (6,35 mm) diameter, 10.0 MHz, 1.5 inch
(38,1 mm) focal distance in water for the inspection of the thread area.
(b) Unfocused Transducer -- 0.250 inch (6,35 mm) minimum diameter, 2.25 MHz
minimum frequency, flat focus transducer as necessary for the inspection of the
head--to--shank.
NOTE: Good results have been obtained with a 0.375 inch diameter (9,51
mm), 10.0 MHz flat focus transducer.
(3) Liquid Couplant -- oil, water or equivalent material. A liquid couplant must be used to
conduct the ultrasonic waves between the transducer and the component that is ex-
amined.
NOTE: Use water, a light oil or equivalent for the liquid couplant for the ultrasonic
bolt inspection. The liquid couplant must not badly affect the bolt or the
equipment.
(4) Bolt Reference Standard -- made from a bolt of similar size and material as the tie bolt
that must be examined. It is recommended an EDM notch(es) be made at the head--
AMASZONAS S.A.

to--shank radius to be the reference notch(es) as shown in Figure 3. The size of the
notch must be:
length: 0.15 inch (3,8 mm) maximum
width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
depth: 5% of the shank diameter.

Part 2
Procedure 2
CO: 8080

32--42--04
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

(5) Bolt Proof Standard -- made from a bolt of similar size and material as the tie bolt that
must be examined. It is recommended EDM notches be made on the third or fourth
complete thread root and in the incomplete thread area as shown in Figure 4. These
notches are used to make sure the ultrasonic inspection is sensitive to cracks in the
bolt threads. The size of the notch must be:

length: 0.15 inch (3,8 mm) maximum

width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
depth: 5% of the shank diameter.

(6) Ultrasonic Bolt Inspection Tank -- able to hold the bolt and the immersion transducer
in the necessary position at the pre--set water path. See Figure 2.

C. See the ultrasonic test equipment, materials and tooling that are available and the vendor
information in the General Information (32--42--03) at the front of this manual.

3. Preparation and Cleaning of a Wheel Tie Bolt

A. Make the end of the bolt that has threads flat and perpendicular to the longitudinal axis of
the bolt. This step must be done before the ultrasonic inspection of the bolt can be done.

NOTE: Use a fixture to hold the bolt perpendicular to the tool used to make the end of
the bolt flat. An example of a fixture is shown in Figure 5.

WARNING: ♦ TIE BOLTS MAY BE COATED WITH CADMIUM. CADMIUM POSES A SERI-
OUS HEALTH HAZARD TO PERSONNEL WHEN EXPOSED TO CADMIUM
DUST PRODUCED DURING DRY GRINDING OR DRY POLISHING OPERA-
TIONS. PERSONNEL PERFORMING GRINDING OR POLISHING OPERA-
TIONS ON CADMIUM COATED TIE BOLTS MUST ADHERE TO THE GUIDE-
LINES CONTAINED IN OSHA GUIDE SECTION 1910.1027 CADMIUM
WHICH IS INCORPORATED HEREIN BY REFERENCE. OPERATORS OUT-
SIDE THE USA SHOULD CONSULT THEIR LOCAL HEALTH AGENCIES
FOR GUIDELINES CONCERNING CADMIUM.

B. Clean the tie bolts as told in the CLEANING section of the applicable Component Mainte-
nance Manual if an ultrasonic inspection will be done on them.
C. After the ultrasonic inspection is done, apply a thin layer of antioxidant coating to the end
of the bolt that was machined to prevent corrosion.
4. Equipment Adjustment for Ultrasonic Inspection of a Wheel Tie Bolt
A. For inspection of the under thread area, install the focused transducer in the bolt inspection
tank.
AMASZONAS S.A.

(1) Put an assumed good bolt in the bolt inspection tank and adjust the distance between
the focused transducer and the bolt face (see Figure 6) to give a water path between
0.4375 and 0.5625 inch (11,112 and 14,288 mm).

NOTE: Other distances can be used if the screen pattern is correct and the proof
notches are found.

Part 2
Procedure 2
CO: 8080

32--42--04
Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

(2) Fill the bolt inspection tank with liquid couplant above the level of the transducer face
and the bolt face (see Figure 6). Lightly rub the transducer face and the bolt face to
remove air bubbles.

(3) Adjust the sweep controls to position the reflection from the end of the bolt on the left
side of the sweep line and to show approximately 2.00 inches (50,8 mm) of metal
travel. Figure 7 shows an acceptable CRT display with the first interface echo at the
‘‘0” position and the second interface echo off the screen.

(4) Move (offset) the transducer centerline away from the bolt centerline and adjust the
gain control in order to get a thread reflection pattern similar to the one shown in
Figure 7. Adjust the gain so that the minimum thread indication amplitude is 20% of
the full screen height (FSH) as the bolt is turned through 360°. The ultrasonic bolt
inspections will be done at this sensitivity level (Primary Reference Level).

(5) Remove the good bolt from the tank and replace it with a bolt proof standard. Turn the
bolt proof standard to make sure the notches in the underthread area are clearly found
at the Primary Reference Level. Figure 8 shows a CRT display of the indication from
the notch 3 to 4 full threads away from the bolt shank of the bolt proof standard.
Figure 9 shows a CRT display of the indication from a notch in the incomplete thread
area of the bolt proof standard.

NOTE: The notches in the proof standard are not reference notches. Do NOT use
these notches as a reference standard. The notch indications as shown in
Figure 8 and Figure 9 should be observed from an inspection of the proof
standard.

B. For inspection of the head--to--shank radius area, install the flat, unfocused transducer in
the bolt inspection tank.

(1) Put an acceptable bolt in the bolt inspection tank and adjust the distance between the
transducer and the bolt face to give a water path that is at least 1/4 the length of the
bolt. See Figure 10 for an example of the water path adjustment for this test.

(2) Fill the bolt inspection tank with liquid couplant above the level of the transducer face
and the bolt face. Lightly rub the transducer face and the bolt face to remove air
bubbles.

(3) Adjust the sweep controls to position the reflection from the polished end of the bolt
(bolt face) on the left side of the sweep line and to show the indication from the entire
length of the bolt towards the right side of the CRT screen. Figure 11 shows the results
of a typical set--up.
AMASZONAS S.A.

(4) Put the bolt reference standard in the bolt inspection tank and adjust the transducer
offset and the gain control to get an indication from the notch at the head and shank
area of the bolt reference standard. See Figure 12. Adjust the gain so this indication
has an amplitude of 20% of the full screen height. This is the Primary Reference Level
for the head--to--shank radius crack inspection.

Part 2
Procedure 2
CO: 8080

32--42--04
Page 3
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

5. Ultrasonic Inspection Procedures for a Wheel Tie Bolts

A. Calibrate the test system as told in paragraph 4., Equipment Adjustment for Ultrasonic In-
spection of a Tie Bolt, for the area to be examined (head--to--shank radius area or bolt thread
area).

B. Put a prepared tie bolt into the bolt inspection tank and move the bolt or the immersion trans-
ducer to direct the sound beam into the area of the bolt to be examined.

NOTE: In the bolt inspection tank made by Rohmann, Incorporated, turn the bolt at least
360° to direct the sound beam into the volume of the bolt.

6. Analysis of a Crack Indication in a Wheel Tie Bolt

A. Thread Area:

(1) During inspection of the thread area, examine a bolt if the signal is very different than
the inverted ‘‘V” pattern given by the threads. See Figure 13 for the CRT display from
an acceptable thread area.

(2) Indications in the thread area which are very different from an acceptable screen pat-
tern similar to the one shown in Figure 13 must be considered cracks.

(3) It is important that both ‘‘positive” crack indications (see Figure 14) and ‘‘negative”
crack indications (see Figure 15) be considered cracks.

B. Head--to--Shank Radius:

(1) During inspection of the head--to--shank radius, examine a bolt if there is an indication
more than the ultrasonic noise level in the bolt between the head of the bolt and the
bolt threads.

(2) Indications in the head--to--shank radius which are greater than 25% of the reference
level are crack indications.

7. Acceptance/Rejection Conditions for a Wheel Tie Bolt

A. A bolt that has crack indications must be discarded.

AMASZONAS S.A.

Part 2
Procedure 2
CO: 8080

32--42--04
Page 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

8. Figures

CRITICAL AREAS

Important Inspection Areas of Wheel Tie Bolts

Figure 1

1 2 3

4
1 ULTRASONIC FLAW DETECTOR 5
2 BOLT INSPECTION TANK

3 BOLT HOLDING FIXTURE (FOR POLISHING)

AMASZONAS S.A.

4 ULTRASONIC TRANSDUCERS

5 REFERENCE STANDARDS

Equipment Used for the Ultrasonic Inspection of Wheel Tie Bolts

Figure 2

Part 2
Procedure 2
CO: 8080

32--42--04
Page 5
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

REFERENCE NOTCH

NOTCH DIMENSIONS
LENGTH WIDTH DEPTH
0.150 MAXIMUM 0.006 + 0.004 5% OF SHANK
(3,81) MAXIMUM (0,15 + 0,10) DIAMETER

Location of Reference Notch in the Bolt Reference Standard for Head to Shank Area
Figure 3

DETAIL B
B

A
DETAIL A

NOTCH A NOTCH B

DETAIL A DETAIL B

NOTCH DIMENSIONS
AMASZONAS S.A.

LENGTH WIDTH DEPTH

0.150 + 0.020 0.006 + 0.004 5% OF SHANK
(3,81 + 0,51) (0,15 + 0,10) DIAMETER

Bolt Proof Standard for Thread Area

Figure 4
Part 2
Procedure 2
CO: 8080

32--42--04
Page 6
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

HOLDING FIXTURE

AMASZONAS S.A.

Example of a Holding Fixture for Making Bolt Ends Flat and Perpendicular
to the Longitudinal Axis of a Bolt Part 2
Figure 5 Procedure 2
CO: 8080

32--42--04
Page 7
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

TRANSDUCER
WATER
PATH
DISTANCE
AMASZONAS S.A.

Water Path Between the Transducer and the Bolt End

Figure 6
Part 2
Procedure 2
CO: 8080

32--42--04
Page 8
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

2ND INTERFACE ECHO

THREAD REFLECTION PATTERN

1ST INTERFACE ECHO
AMASZONAS S.A.

Indication Pattern from an Acceptable Thread Area

Figure 7
Part 2
Procedure 2
CO: 8080

32--42--04
Page 9
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

NOTCH INDICATION

AMASZONAS S.A.

Indication from a Notch 3 to 4 Threads from the Bolt Shank

Figure 8 Part 2
Procedure 2
CO: 8080

32--42--04
Page 10
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

NOTCH INDICATION
AMASZONAS S.A.

Indication from a Notch in the Incomplete Thread Area

Figure 9
Part 2
Procedure 2
CO: 8080

32--42--04
Page 11
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

WATER PATH
1/4 OF BOLT
LENGTH MINIMUM FLAT TRANSDUCER AMASZONAS S.A.

Water Path Adjustment for the Head--to--Shank Ultrasonic Inspection

Figure 10
Part 2
Procedure 2
CO: 8080

32--42--04
Page 12
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

INDICATION(S) FROM
HEAD OF BOLT

1ST BOLT END SIGNAL

INDICATION FROM NOTCH

IN MID--SHANK AREA
AMASZONAS S.A.

Typical CRT Display with an Indication from a Mid--Shank Notch

Figure 11
Part 2
Procedure 2
CO: 8080

32--42--04
Page 13
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

INDICATION FROM NOTCH

IN HEAD--TO--SHANK AREA
AMASZONAS S.A.

Indication from a Head--To-- Shank Notch

Figure 12
Part 2
Procedure 2
CO: 8080

32--42--04
Page 14
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

THREAD REFLECTION PATTERN

AMASZONAS S.A.

Ultrasonic Indication Pattern from an Acceptable Thread Area of a Wheel Tie Bolt
Figure 13
Part 2
Procedure 2
CO: 8080

32--42--04
Page 15
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

‘‘POSITIVE” INDICATION OF
FATIGUE CRACK

AMASZONAS S.A.

‘‘Positive” Fatigue Crack Indication in the Thread Area of a Wheel Tie Bolt
Figure 14
Part 2
Procedure 2
CO: 8080

32--42--04
Page 16
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

‘‘NEGATIVE” INDICATION OF
FATIGUE CRACK

AMASZONAS S.A.

‘‘Negative” Fatigue Crack Indication in the Thread Area of a Wheel Tie Bolt
Figure 15
Part 2
Procedure 2
CO: 8080

32--42--04
Page 17
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
ULTRASONIC INSPECTION

THIS PAGE
KEPT
BLANK

AMASZONAS S.A.

Part 2
Procedure 2
CO: 8080

32--42--04
Page 18
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

TABLE OF CONTENTS

SUBJECT PAGE

PART 3 -- EDDY CURRENT INSPECTION (32--42--05)

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning 2
4. Equipment Adjustment for Eddy Current Inspection 3
5. Eddy Current Inspection Procedures 3
6. Analysis of Crack Indications 5
7. Acceptance/Rejection Conditions for Component with Crack Indications 5
8. Figures 6

AMASZONAS S.A.

Part 3
Table of Contents
CO: 8080

Page 1
32--42--05 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

TABLE OF FIGURES

FIGURE PAGE

PART 3 -- EDDY CURRENT INSPECTION (32--42--05)

(PROCEDURE 1 -- CRACK INSPECTION)
Figure 1 NDT Areas for a Wheel Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2 Reference Notch for Forged Aluminum Components . . . . . . . . . . . . . . . . . . 7
Figure 3 Reference Notch for Cast Aluminum and Cast Magnesium Components . 7
Figure 4 Impedance Plane Eddy Current Instrument (Example) . . . . . . . . . . . . . . . . 8
Figure 5 Test Coil (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6 Wide Scan Wheel Probe (Custom Made) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7 Semi--Automatic Wheel Bead Seat Testing System . . . . . . . . . . . . . . . . . . . 11
Figure 8 Manual Eddy Current Probe Guide for Bead Seat Testing . . . . . . . . . . . . . . 12
Figure 9 Reference Standards for a Semi--Automatic Test System . . . . . . . . . . . . . . 13
Figure 10 Reference Standard for a Contoured Test Coil . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 11 Typical Flat Eddy Current Reference Standard Plate
(with notches and radii) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 12 Bolt Hole Reference Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 13 Special Reference Standard and Contoured Test Coil
(for a Wheel Subassembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 14 Impedance Plane Reference Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 15 Calibration Response for a Special Reference Standard and
Contoured Test Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 16 Scan Paths for Manual Eddy Current Inspection of the
Bead Seat and Tubewell Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 17 Fatigue Crack Indication (2 scans across the indication) . . . . . . . . . . . . . . . 21
Figure 18 Length and Width Measurement of a Crack Indication . . . . . . . . . . . . . . . . . 22
Figure 19 Eddy Current Indication Crack Analysis (Impedance Plane Method) . . . . . 23

AMASZONAS S.A.

Part 3
Table of Contents
CO: 8080

Page 2
32--42--05 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

PART 3 -- EDDY CURRENT INSPECTION

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity
A. An eddy current inspection must be done on the wheel bead seat area and the adjacent
tubewell area of all wheel subassemblies.
NOTE: Alternatively, an ultrasonic inspection can be done on the wheel bead seat area
and the adjacent tubewell area of all wheel subassemblies. See PART 2,
Ultrasonic Inspection.
B. An eddy current inspection must be done on all other areas of the wheel subassemblies
where abrasion can smear the metal and cause the penetrant inspection not to find cracks.
See Figure 1.
C. An eddy current inspection must be done on all areas of the nonmagnetic components of
the brake assemblies (brake housings) in the areas shown in the applicable Component
Maintenance Manual.
2. Tooling and Equipment
A. Eddy current inspections can use many different instruments each with its own procedures.
It is recommended that the equipment used (and the procedure done) be able to find the
reference standards given when test frequencies in the range of 100 kHz to 500 kHz are
used. Also, the equipment must be operated as told in the manufacturer’s instructions and
as told in the procedures that follow.
B. Eddy Current Equipment, Materials and Tooling parameters:
(1) Reference Standard -- made locally as necessary or bought from a supplier. The refer-
ence notch dimensions are as follows:
NOTE: When the eddy current method is used as an alternative for the penetrant
inspection in forged aluminum components, a reference standard with an
0.120 +0.012 inch (3,05 +0,30 mm) length notch must be used as the refer-
ence notch. See Figure 3.

When the eddy current method is used as an alternative for the penetrant
inspection in cast aluminum and magnesium components, a reference
standard with a standard notch (1.0 inch +0.01 inch length x 0.040 inch
+0.004 inch depth x 0.006 inch +0.004 inch wide) is recommended.
(a) Forged Aluminum Components (See Figure 2)
length: 0.060 + 0.006 inch (1,52 + 0,15 mm)
width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
AMASZONAS S.A.

depth: 0.030 + 0.003 inch (0,76 + 0,08 mm)

(b) Cast Aluminum and Magnesium Components (See Figure 3)
length: 0.120 + 0.012 inch (3,05 + 0,30 mm)
width: 0.006 + 0.004 inch (0,15 + 0,10 mm)
depth: 0.030 + 0.003 inch (0,76 + 0,08 mm)

Part 3
Procedure 1
CO: 8080

32--42--05
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

(2) Test Instrument -- Hocking Phase 2200 or equivalent. Refer to Figure 4 for an example
of an impedance plane eddy current instrument.

(3) Test Coils

(a) 0.125 inch (3,18 mm) diameter, absolute, shielded test coil. The test coil must be
able to operate in a range between 100 kHz and 500 kHz. Refer to Figure 5 for
examples of test coils.

(b) Custom Test Coil (Bead seat and tubewell areas only) -- able to examine the com-
plete bead seat area in one or two passes. See Figure 7.

(4) Wheel Test System

(a) Semi--Automatic Bead Seat Scanning System -- See Figure 7.

(b) Manual System -- uses pencil probes with or without probe guides. See Figure 8.

C. See the eddy current test equipment, materials and tooling that are available and the vendor
information in the General Information (32--42--03) at the front of this manual.

3. Preparation and Cleaning

A. Clean all areas of the component that must have an eddy current inspection as told in the
CLEANING section of the applicable Component Maintenance Manual.

B. Remove all loose paint, tire rubber and other unwanted material from the wheel subassem-
bly in the area that must be examined.

NOTE: If the paint is not loose or not more than 3 mil (0,076 mm) thick and is in good
condition, it is not necessary to remove paint before an eddy current inspection.

C. Make or purchase the reference standard for the component to be examined. Make sure
the appropriate size notch is made in the reference standard for the material that must be
examined (see paragraph 2.B.).

(1) Wheel Bead Seat and Tubewell Reference Standards:

NOTE: The material size and shape of the reference standard must agree with the
test equipment that will be used. The conductivity (%) of the material that
is used for the reference standard must be within 10% of the conductivity
of the material that must be examined (for example test piece is 38% IACS,
reference material may be 28 -- 48% IACS).

(a) When semi--automatic test systems are used for inspection of the wheel bead
AMASZONAS S.A.

seat area, it is recommended the reference notches be made in a wheel dis-

carded for reasons other than cracks in the bead seat or tubewell. See Figure 9.

(b) When contoured test coils are used for inspection of the wheel bead seat area,
a piece of the wheel subassembly to be examined must be used for the reference
standard. See Figure 10.

Part 3
Procedure 1
CO: 8080

32--42--05
Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

(2) Reference Standards for All Other Wheel Subassembly Areas and Brake Housing
Reference Standards:

NOTE: The material size and shape of the reference standard must agree with the
test equipment that will be used. The conductivity (%) of the material that
is used for the reference standard must be within 10% of the conductivity
of the material that must be examined.

(a) Make the reference notch in a piece of material with properties similar to the prop-
erties of the component to be examined. See Figure 11 for a flat standard refer-
ence standard plate.

(b) For bolt hole inspections, make a reference standard similar to the one shown
in Figure 12.

(c) When contoured test coils are used, make the reference from a piece of the
particular component in the area where the eddy current inspection must be
done. See Figure 13 for an example of contoured test coils for an eddy current
inspection of one type of aircraft wheel.

4. Equipment Adjustment for Eddy Current Inspection

A. Turn the test instrument on and connect the appropriate test coil as told in the equipment
manufacturer’s instructions. Make the initial instrument adjustments as necessary.

B. Scan the test coil over the reference notch and adjust the test instrument to get a minimum
signal of 40% of full scale height (FSH).

NOTE: When a manual scan is done, the scan speed during calibration must be approxi-
mately the same as the scan speed used for the actual inspection.

(1) See Figure 14 for an example of an impedance plane reference signal for a wheel
bead seat inspection.

(2) For the test coil and reference standard shown Figure 13, the eddy current signal will
be similar to Figure 15.

5. Eddy Current Inspection Procedures

A. For an eddy current inspection of the wheel bead seat and tube well areas:

(1) Calibrate the eddy current instrument and test coil as told in paragraph 4., Equipment
Adjustment for Eddy Current Inspection.
AMASZONAS S.A.

(2) Put the test coil on the bead seat and balance the instrument and adjust the controls
to get a lift--off response similar to the response given for the reference standard.

NOTE: This step is not necessary for semi--automatic test systems unless the
manufacturer’s instructions make this necessary.

Part 3
Procedure 1
CO: 8080

32--42--05
Page 3
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

(3) Make a scan of the bead seat and the adjacent tubewell areas. Make sure the scan
includes 100% of the areas that must be examined.

(a) Two types of scan paths which can be used for pencil probes during the scan op-
eration of the tubewell and bead seat areas are shown in Figure 16. Either of
these scan types will cover 100% of the necessary inspection area.

NOTE: To make sure 100% of the critical bead seat and tubewell areas are
examined during a manual eddy current scan, apply penetrant devel-
oper on the wheel subassembly and follow the path of the test coil
through the penetrant developer.

B. For an eddy current inspection of wheel subassemblies (except the bead seat and tubewell
areas) and brake housings:

(1) Calibrate the eddy current instrument and test coil as told in paragraph 4., Equipment
Adjustment for Eddy Current Inspection.

(2) Put the test coil on the component in the area that must be examined and balance the
instrument and adjust the controls to get a lift--off response similar to the response giv-
en for the reference standard.

(3) Make a scan of the area that must be examined. Make sure the scan includes 100%
of the areas that must be examined.

(a) To make sure 100% of the area is examined when a manual pencil probe is used,
apply penetrant developer to the inspection area and follow the path of the test
coil (pencil probe) through the penetrant developer.

(b) When pencil probes are used to examine several areas of the component, locally
made probe holders which do not cause damage to the component can be used
to make sure all of the areas are examined. A probe holder can also be used to
keep the position of the test coil in relation to the component surface constant.

C. An indication which is more than 50% of the reference standard notch indication must be
examined as told in paragraph 6., Analysis of Crack Indications. See Figure 17 for an exam-
ple of a crack indication.

AMASZONAS S.A.

Part 3
Procedure 1
CO: 8080

32--42--05
Page 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

6. Analysis of Crack Indications

A. Not all eddy current indications are caused by fatigue cracks in the component. This is true
when cast alloy components are examined. To make a decision as to whether an indication
is a fatigue crack, compare the length to width of the indication as follows:
NOTE: It is necessary to do the procedures that follow for cast aluminum or cast magne-
sium components. See the DESCRIPTION AND OPERATION section of the ap-
plicable Component Maintenance Manual to find whether the component that
must be examined is made from cast aluminum or cast magnesium. The proce-
dures that follow can also be done for forged aluminum components if necessary.
(1) Move the eddy current test coil along the length of the indication and identify each end
of the indication where the indication is below 50% of the reference signal. Measure
the distance between these two points. This is the length of the indication. See
Figure 18 for an example of points where the length and width indications are below
50% of the reference signal as the test coil moves away from the maximum indication.
(2) Move the eddy current test coil along the width of the indication and identify each end
of the indication where the indication is below 50% of the reference signal. Measure
the distance between these two points. This is the width of the indication. See
Figure 18.
(3) Divide the length of the indication by the width of the indication. If the result is greater
than 3.0, the indication is most likely a fatigue crack and the component must be re-
moved from service.
(4) Alternatively, an impedance plane eddy current instrument (CRT or Flying Dot) can
be used to make an analysis of the type of discontinuity that causes a crack indication.
A crack indication will appear as shown in Figure 19.
(5) If both procedures are used to make an analysis of a crack indication, the inspector
has the ability to characterize the discontinuity that caused the indication. This makes
sure that components are disposed of correctly.
B. Components made from castings that have linear indications of fatigue cracks greater than
100% of the reference standard notch indication must be removed from service.
C. Components made from forgings that have linear indications of fatigue cracks greater than
100% of the reference standard notch indication must be removed from service.
7. Acceptance/Rejection Conditions for Components with Crack Indications
A. Remove a wheel subassembly or a brake housing from service if it has a fatigue crack.
B. Repair the area where the crack indication was found as told in the REPAIR section of the
AMASZONAS S.A.

applicable Component Maintenance Manual. Do not remove more material from the area
of the fatigue crack than the limits given in the applicable Component Maintenance Manual.
C. Do a second eddy current inspection (or an ultrasonic inspection if applicable) on the com-
ponent after the fatigue cracks are repaired. If the component still has fatigue cracks, dis-
card the component.

Part 3
Procedure 1
CO: 8080

32--42--05
Page 5
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

8. Figures

1 2

0.25 (6,35) BEYOND TANGENT POINT

NOTES:

1 DO AN EDDY CURRENT INSPECTION ON THIS AREA.

2 ALTERNATIVELY, DO AN ULTRASONIC INSPECTION OF THE AREA.

3 DO AN EDDY CURRENT INSPECTION OF THESE AREAS IF ABRASION HAS

SMEARED THE METAL.
AMASZONAS S.A.

4. DO A PENETRANT INSPECTION TO EXAMINE ALL OTHER AREAS OF THE

WHEEL SUBASSEMBLY.

NDT Areas for a Wheel Subassembly

Figure 1
Part 3
Procedure 1
CO: 8080

32--42--05
Page 6
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

0.006 + 0.004 (0,15 + 0,10)

0.06 + 0.006 (1,52 + 0,15)

0.030 (0,76)

LONG VIEW END VIEW

Reference Notch for Forged Aluminum Components

Figure 2

0.006 + 0.004 (0,15 + 0,10)

0.120 + 0.012 (3,05 + 0,30)

0.030 (0,76)

LONG VIEW END VIEW AMASZONAS S.A.

Reference Notch for Cast Aluminum and Cast Magnesium Components

Figure 3

Part 3
Procedure 1
CO: 8080

32--42--05
Page 7
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

AMASZONAS S.A.

DETAIL OF SCREEN DISPLAY

Impedance Plane Eddy Current Instrument (Example)

Figure 4
Part 3
Procedure 1
CO: 8080

32--42--05
Page 8
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

AMASZONAS S.A.

Test Coil (Example)

Figure 5
Part 3
Procedure 1
CO: 8080

32--42--05
Page 9
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

THIS AREA MOLDED TO THE

INDIVIDUAL WHEEL CONTOUR
0.25 (6,35)
BEYOND
TANGENT
POINT

WHEEL BEAD CROSS SECTION

AMASZONAS S.A.

Wide Scan Wheel Probe (Custom Made)

Figure 6 Part 3
Procedure 1
CO: 8080

32--42--05
Page 10
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

AMASZONAS S.A.

TEST COILS IN BEAD RADIUS

Semi--Automatic Wheel Bead Seat Testing System

Figure 7 Part 3
Procedure 1
CO: 8080

32--42--05
Page 11
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

PROBE PIVOT POINT

GUIDE BLOCK
ASSEMBLY

RADIUS

PLASTIC SLIDE

NUMBER OF TEST COIL POSITIONS

TO MAKE SURE THE AREA IS FULLY
EXAMINED

NOTES:
AMASZONAS S.A.

1. OTHER TYPES OF PROBE HOLDERS MAY BE USED PROVIDED

ADEQUATE COVERAGE IS OBTAINED

Manual Eddy Current Probe Guide for Bead Seat Testing

Figure 8 Part 3
Procedure 1
CO: 8080

32--42--05
Page 12
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

0.060 (1,52) LONG NOTCH FOR FORGED MATERIAL

AMASZONAS S.A.

0.120 (3,05) LONG NOTCH FOR CAST MATERIAL

Reference Standards for a Semi--Automatic Test System

Figure 9 Part 3
Procedure 1
CO: 8080

32--42--05
Page 13
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

AMASZONAS S.A.

Reference Standard for a Contoured Test Coil

Figure 10 Part 3
Procedure 1
CO: 8080

32--42--05
Page 14
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

E.D.M. NOTCH DEPTH

0.030 (0,76)

0.020 (0,51)
0.062 (1,57)
0.010 (0,25) RAD

0.100 (2,54)
RAD
0.030 (0,76)

NOTES:

1. FOR FORGED MATERIAL NOTCH DIMENSIONS SHOULD BE

AMASZONAS S.A.

0.060 LONG X 0.006 WIDE (1,52 X 0,76 X 0,15) FOR CRITICAL AREA.

2. FOR CAST MATERIAL NOTCH DIMENSIONS SHOULD BE

0.120 LONG X 0.006 WIDE (3,05 X 0,76 X 0,15) FOR CRITICAL AREA.

Typical Flat Eddy Current Reference Standard Plate (with notches and radii)
Figure 11
Part 3
Procedure 1
CO: 8080

32--42--05
Page 15
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

d 1
DETAIL A

DETAIL A

NOTES:
1 ‘‘d” IS THE NOMINAL DIAMETER OF THE BOLT HOLE
2. SQUARE CORNER IS TYPICAL IN A REFERENCE BLOCK
AMASZONAS S.A.

Bolt Hole Reference Standard

Figure 12 Part 3
Procedure 1
CO: 8080

32--42--05
Page 16
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

LOCATION
0.030 +0.030
COIL (0,76 +0,76)
#1 1

0.160 +0.015
(4,06 +0,38)

#2 1

TEST COIL

NOTES:
AMASZONAS S.A.

1 #1 AND #2 ARE E.D.M. NOTCHES AS GIVEN IN THE APPLICABLE

REQUIREMENTS

Special Reference Standard and Contoured Test Coil (for a Wheel Subassembly)
Figure 13
Part 3
Procedure 1
CO: 8080

32--42--05
Page 17
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

NOTCH SIGNAL

LIFT--OFF INDICATION
AMASZONAS S.A.

Impedance Plane Reference Signal (Example)

Figure 14 Part 3
Procedure 1
CO: 8080

32--42--05
Page 18
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

INDICATION FROM BEAD SEAT NOTCH WITH WIDE SCAN COIL

INDICATION FROM
NOTCH #1
(SEE FIGURE 13)

LIFT--OFF

LIFT--OFF

INDICATION FROM
AMASZONAS S.A.

NOTCH #2
(SEE FIGURE 13)

Calibration Response for a Special Reference Standard and Contoured Test Coil
Figure 15
Part 3
Procedure 1
CO: 8080

32--42--05
Page 19
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

3
3 3

1
1

4 4
2

NOTES:
1 MINIMUM WIDTH OF TUBEWELL SCAN, 0.25 (6,35) ABOVE TANGENT LINE

2 MINIMUM WIDTH OF SCAN ON FLANGE, 0.13--0.25 (3,3--6,35) BEYOND

TANGENT WITH BEAD SEAT RADIUS

3 SCAN INDEX MUST BE NO MORE THAN 75% OF TEST COIL DIAMETER

4 OVERLAP OF SCANNING AREAS AMASZONAS S.A.

Scan Paths for Manual Eddy Current Inspection of the Bead Seat and Tubewell Areas
Figure 16
Part 3
Procedure 1
CO: 8080

32--42--05
Page 20
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

CRACK INDICATION

LIFT--OFF

AMASZONAS S.A.

Fatigue Crack Indication (2 scans across the indication)

Figure 17
Part 3
Procedure 1
CO: 8080

32--42--05
Page 21
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

10 10 10
9 9 9
8 8 8
7 3 7 1 7 3
6 6 6
5 5 5
4 4 4
3 3 3
2 2 2
1 1 1
0 0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 9 10 11 12 0 1 2 3 4 5 6 7 8 9 10 11 12

MAXIMUM SIGNAL

WIDTH

10
9
8
2 7
2
6
5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12

10
1 9
8 1
7
6
5
3 LENGTH 4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12

MAXIMUM SIGNAL

10
9
8
7
6 2
5
4
2 3
2
1
0
NOTES: 0 1 2 3 4 5 6 7 8 9 10 11 12

1 MAXIMUM INDICATION -- SIGNAL IS MORE THAN 50% OF THE REFERENCE

STANDARD VALUE
AMASZONAS S.A.

2 END OF INDICATION LENGTH -- SIGNAL IS APPROXIMATELY 50% OF THE

REFERENCE STANDARD VALUE
3 END OF INDICATION WIDTH -- SIGNAL IS APPROXIMATELY 50% OF THE
REFERENCE STANDARD VALUE

Length and Width Measurement of a Crack Indication

Figure 18 Part 3
Procedure 1
CO: 8080

32--42--05
Page 22
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

THIS INDICATION DID NOT REPRESENT A CRACK

AMASZONAS S.A.

THESE INDICATIONS DID REPRESENT A CRACK

Eddy Current Indication Crack Analysis (Impedance Plane Method)

Figure 19 Part 3
Procedure 1
CO: 8080

32--42--05
Page 23
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
EDDY CURRENT INSPECTION

THIS PAGE
KEPT
BLANK

AMASZONAS S.A.

Part 3
Procedure 1
CO: 8080

32--42--05
Page 24
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

TABLE OF CONTENTS

SUBJECT PAGE

PART 4 -- MAGNETIC PARTICLE INSPECTION (32--42--06)

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning 1
4. Equipment Adjustment for Magnetic Particle Inspection 1
5. Magnetic Particle Inspection Procedures 2
6. Analysis of Crack Indications 2
7. Acceptance/Rejection Conditions for Component with Crack Indications 3
8. Figures 4

AMASZONAS S.A.

Part 4
Table of Contents
CO: 8080

Page 1
32--42--06 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

TABLE OF FIGURES

FIGURE PAGE

PART 4 -- MAGNETIC PARTICLE INSPECTION (32--42--06)

(PROCEDURE 1 -- CRACK INSPECTION)
Figure 1 Circular Magnetization in a Head Shot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2 Longitudinal Magnetization in a Coil Shot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Central Conductor Circular Magnetization of a Torque Tube . . . . . . . . . . . . . . 5
Figure 4 Longitudinal Magnetization of a Torque Tube with a Coil . . . . . . . . . . . . . . . . . . 6

AMASZONAS S.A.

Part 4
Table of Contents
CO: 8080

Page 2
32--42--06 Mar 01/05
CO: 8080 AMASZONAS S.A. EMAIL: milton.ballesteros@amaszonas.com
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL

TEMPORARY REVISION NO. 32--2

FILING INSTRUCTIONS: Insert facing Part 4, Procedure 1, page 1 (32--42--06).

DESCRIPTION: Added ultrasonic inspection as alternate. Removed “tie’’ from paragraph 1.A. and
NOTE.

1 Effectivity

B. An ultrasonic inspection can be done on the ferromagnetic and non ferromagnetic bolts as
an alternative for the magnetic particle inspection or the florescent penetrant inspection. See
PART 2, Procedure 2.

NOTE: Alternatively, an ultrasonic inspection can be done to find cracks in the bolts as
told in PART 2 -- Ultrasonic Inspection. Alternatively, an eddy current inspection
can also be done to find cracks using a reference notch no larger than the
reference notch required for inspection of critical area of the bolts.

AMASZONAS S.A.
CO: 8080

Page 3 of 3
May 16/11
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

PART 4 -- MAGNETIC PARTICLE INSPECTION

(PROCEDURE 1 -- CRACK INSPECTION)

1. Effectivity

A. A magnetic particle inspection can be used to find cracks in all ferromagnetic tie bolts. The
magnetic particle inspection must be done as told in ASTM--E1444 or an equivalent
magnetic particle process specification.

NOTE: Alternatively, an ultrasonic inspection can be done to find cracks in the tie bolts
as told in PART 2 -- Ultrasonic Inspection. Alternatively, an eddy current inspec-
tion can also be done to find cracks using a reference notch no larger than the
reference notch required for inspection of critical area of the bolts.

B. A magnetic particle inspection must be used to find cracks in all ferromagnetic brake com-
ponents (steel bolts, ferromagnetic torque tubes and other ferromagnetic components) that
must have an inspection. The magnetic particle inspection must be done as told in ASTM--
E1444 or an equivalent magnetic particle process specification.

2. Tooling and Equipment

A. Magnetic Particle Inspection Equipment, Materials and Tooling parameter:

(1) Magnetic Field(s) -- must be able to find crack indications in a surface in all orienta-
tions. Magnetizing value(s) for component inspection must be as told in Specification
ASTM--E1444, Standard Practice for Magnetic Particle Examination, or an equivalent
magnetic particle process specification.

(2) Wet Magnetic Particles -- must obey the standards given in Specification ASTM--
E1444.

B. Magnetic particle inspection equipment, materials and tooling -- See vendor information in
the General Section of this manual.

3. Preparation and Cleaning

A. Disassemble the wheel assembly or the brake assembly as told in the DISASSEMBLY sec-
tion of the applicable Component Maintenance Manual. Do not remove components from
a wheel assembly or brake assembly (bearing cups, thread inserts or other similar items)
that can cause permanent damage to the wheel subassembly or the brake housing unless
the removal of these items is done because of the possibility of a fatigue crack in the area.

B. Clean the component to be examined as told in the CLEANING section of the applicable
Component Maintenance Manual.

4. Equipment Adjustment for a Magnetic Particle Inspection

AMASZONAS S.A.

A. Put the component to be examined in the magnetic field so the magnetic field passes
through the surface of the part in two directions perpendicular to each other as shown in
Figure 1, Figure 2, Figure 3 and Figure 4.

NOTE: Do not use permanent magnets to do this inspection.

Part 4
Procedure 1
CO: 8080

32--42--06
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

B. Use the wet continuous method of magnetic particle examination to examine the parts for
fatigue cracks.

C. Set the magnetizing values for the magnetic fields as told in ASTM--E1444, Standard Prac-
tice for Magnetic Particle Examination, or an equivalent magnetic particle process specifi-
cation.

5. Magnetic Particle Inspection Procedures

A. Inspect all parts in areas where fatigue is likely to be a cause of failure. Pay special attention
to inner corners, radii and areas of wear on each component. For bolts, pay special attention
to the radius between the bolt head and bolt shank, and to the area near the third and fourth
complete thread root from the shank.

NOTE: The area immediately adjacent to the last threads that engage the nut or
threaded hole is most suspect of crack origination.

B. Use full wave rectified alternating current (3 phase or 1 phase), half--wave rectified alternat-
ing current or alternating current in the magnetic power source.

NOTE: Permanent magnets are not recommended.

C. Wet magnetic particles and suspension vehicles must be used as told in ASTM--E1444.

D. Whenever possible, the longitudinal magnetization of a component must be done after all
circumferential magnetizations are done.

E. If the magnetizing force used for a magnetization is less than the magnetization force used
for a preceding magnetization, a demagnetization is necessary between magnetizing op-
erations.

6. Analysis of Crack Indications

A. Fatigue crack orientation is usually perpendicular to the direction of stress. Nonrelevant

crack like indications can occur where:

(1) Sudden changes in the thickness of a section occur.

(2) Parts are press fitted together (example: a bushing press fitted into a bore).

(3) Sudden changes in the magnetic permeability occur (example: a welded area or a cold
rolled area).

B. Whenever possible, magnetic particle crack indications must be investigated by a different

nondestructive test procedure.
AMASZONAS S.A.

(1) Use a technique that can find crack indications on the surface of the component. See
PART 3 -- Eddy Current Inspection.

(2) Inspectors must be careful not to reject components due to false or irrelevant crack
indications.

Part 4
Procedure 1
CO: 8080

32--42--06
Page 2
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

7. Acceptance/Rejection Conditions for a Component with Crack Indications

A. Components that have crack indications must be removed from service.

B. Repair the area where the crack indication was found as told in the REPAIR section of the
applicable Component Maintenance Manual. Do not remove more material from the area
of the fatigue crack than the limits given in the applicable Component Maintenance Manual.

C. Do a second magnetic particle inspection on the component after the fatigue cracks are re-
paired. If the component still has fatigue cracks, discard the component.

NOTE: It is recommended that components that have crack indications be examined by

a more sensitive method (eddy current inspection) in the area of the crack indica-
tions before they are discarded.

AMASZONAS S.A.

Part 4
Procedure 1
CO: 8080

32--42--06
Page 3
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

8. Figures

WHEEL DRIVE KEY

HEAD STOCK

NOTE: TAIL STOCK

1. THE ARROW SHOWS THE DIRECTION OF THE MOST EASILY FOUND FLAW.

Circular Magnetization in a Head Shot

Figure 1

AMASZONAS S.A.

NOTE: WHEEL DRIVE KEY

1. THE ARROWS SHOW THE DIRECTION OF THE MOST EASILY FOUND FLAW.

Longitudinal Magnetization in a Coil Shot

Figure 2

Part 4
Procedure 1
CO: 8080

32--42--06
Page 4
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

HEAD STOCK

CENTRAL CONDUCTOR

4D
2

TORQUE TUBE

TAIL STOCK

NOTE:

1. THE ARROW SHOWS THE DIRECTION OF THE MOST EASILY FOUND FLAW.

2 4D (4 x CENTRAL CONDUCTOR DIAMETER) REPRESENTS THE MAXIMUM

AREA OF INSPECTION ADJACENT TO THE CONDUCTOR AMASZONAS S.A.

Central Conductor Circular Magnetization of a Torque Tube

Figure 3
Part 4
Procedure 1
CO: 8080

32--42--06
Page 5
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
MAGNETIC PARTICLE INSPECTION

MAGNETIZING COIL

TORQUE TUBE

NOTE:

1. THE ARROWS SHOW THE DIRECTION OF THE MOST EASILY FOUND FLAW.

AMASZONAS S.A.

Longitudinal Magnetization of a Torque Tube with a Coil

Figure 4
Part 4
Procedure 1
CO: 8080

32--42--06
Page 6
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
PENETRANT INSPECTION

TABLE OF CONTENTS

SUBJECT PAGE

PART 5 -- PENETRANT INSPECTION (32--42--07)

(PROCEDURE 1 -- CRACK INSPECTION)
1. Effectivity 1
2. Tooling and Equipment 1
3. Preparation and Cleaning 1
4. Equipment Adjustment 1
5. Penetrant Inspection Procedures 1
6. Analysis of Crack Indications 2
7. Acceptance/Rejection Conditions for Component with Crack Indications 2
8. Figures 2

AMASZONAS S.A.

Part 5
Table of Contents
CO: 8080

Page 1
32--42--07 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
PENETRANT INSPECTION

TABLE OF FIGURES

FIGURE PAGE

N/A

AMASZONAS S.A.

Part 5
Table of Contents
CO: 8080

Page 2
32--42--07 Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
PENETRANT INSPECTION

PART 5 -- PENETRANT INSPECTION

(PROCEDURE 1 -- CRACK INSPECTION)

1. Effectivity

A. A penetrant inspection can be used to find cracks in all non--ferromagnetic wheel and brake
components that must have a crack inspection. The penetrant inspection must be done as
told in ASTM E1417 or equivalent fluorescent penetrant inspection process specification.

B. A penetrant inspection can be used to find cracks in all nonporous, ferromagnetic wheel and
brake components, if necessary.

2. Tooling and Equipment

NOTE: ABSC only recommends the use of fluorescent penetrant inspections. Other dye
penetrant inspections must not be used on ABSC components.

A. See the fluorescent penetrant fluids that are available and the vendor information in the
General Information (32--42--03) at the front of this manual. Equivalent replacements can
be used for the items given. Any combination of approved Type I materials can be used if
the sensitivity is level 2 or more. Refer to Specifications SAE AMS 2644 and QPL--2644.

3. Preparation and Cleaning

A. Disassemble the wheel assembly or the brake assembly as told in the DISASSEMBLY sec-
tion of the applicable Component Maintenance Manual. Do not remove components from
a wheel assembly or brake assembly (bearing cups, thread inserts or other similar items)
that can cause permanent damage to the wheel subassembly or the brake housing unless
the removal of these items is done because of the possibility of a fatigue crack in the area.

CAUTION: ♦ MAKE SURE THE PARTS ARE CLEAN AND DO NOT HAVE CONTAMINATION.
THE ACCURACY OF THE PENETRANT INSPECTION WILL DECREASE IF
THE PARTS HAVE CONTAMINATION.

B. Clean the component to be examined as told in the CLEANING section of the applicable
Component Maintenance Manual.

C. Remove the paint from the component as told in the CLEANING section of the applicable
Component Maintenance Manual.

4. Equipment Adjustment

A. Not applicable.
AMASZONAS S.A.

5. Penetrant Inspection Procedures

A. Penetrant inspection must be done as told in a fluorescent penetrant processing specifica-

tion such as ASTM 1417. The penetrant materials must conform to SAE AMS 2644, Type
1, sensitivity level 2.

Part 5
Procedure 1
CO: 8080

32--42--07
Page 1
Mar 01/05
 EMAIL: milton.ballesteros@amaszonas.com
NONDESTRUCTIVE TESTING MANUAL
PENETRANT INSPECTION

6. Analysis of a Crack Indication

A. Make a decision as to whether each crack indication is false, not important or important.

(1) False indications are indications caused by poor removal of developer, the use of too
much developer, or contamination of the component during examination.

(2) Indications that are not important are indications that are caused by discontinuities in
the design of the component. For example, an indication can be caused by the press
fit of a bushing into a hole.

(3) Important indications are indications of true discontinuities.

7. Acceptance/Rejection Conditions for a Component with Crack Indications

A. Indications that are considered important are fatigue cracks. Components with fatigue
cracks must be removed from service. It is recommended that these components be ex-
amined by a different NDT procedure (eddy current inspection) to make sure the indication
is a fatigue crack.

CAUTION: ♦ DO NOT REPAIR CRACKS UNLESS THE COMPONENT MAINTENANCE

MANUAL SPECIFIES THE REPAIR IS WITHIN THE LIMITS.
♦ REPAIR OF CRACKS IS VERY LIMITED AND MUST BE EXPLICITLY PER-
MITTED FOR THE AREA IN THE APPLICABLE COMPONENT MAINTE-
NANCE MANUAL.

B. Repair the area where the crack indication was found as told in the REPAIR section of the
applicable Component Maintenance Manual. Do not remove more material from the area
of the fatigue crack than the limits given in the applicable Component Maintenance Manual.

C. Do a second fluorescent penetrant inspection on the component after the fatigue cracks are
repaired. If the component still has fatigue cracks, discard the component.

NOTE: It is recommended that components that have crack indications be examined by

a more sensitive NDT procedure (eddy current inspection) in the area of the
crack indications before they are discarded.

8. Figures

A. Not applicable.
AMASZONAS S.A.

Part 5
Procedure 1
CO: 8080

32--42--07
Page 2
Mar 01/05
CO: 8080 AMASZONAS S.A. EMAIL: milton.ballesteros@amaszonas.com
CO: 8080 AMASZONAS S.A. EMAIL: milton.ballesteros@amaszonas.com