NONDESTRUCTIVE INSPECTION METHODS, BASIC …

1 33B-1-1 NAVAIR 01-1A-16TM 1-1500-335-23 TECHNICAL MANUALNONDESTRUCTIVE INSPECTIONMETHODS, BASIC THEORY(ATOS)THIS MANUAL SUPERSEDES 33B-1-1, DATED 1 JANUARY 2005, AND ALL SUBSEQUENT MANUAL HAS BEEN EXTENSIVELY REWRITTEN; THEREFORE, REVISION BARS HAVE BEEN the text of this manual refers to Air Force technical orders for supportive information,PERSONNEL:refer to the comparable Army instruction and weapon system specific manuals take precedence over this :DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. PA Case Number SPR50014. Submit recommendedchanges or problems with this Technical Order to 558 under Authority of the Secretary of the Air Force15 JUNE 33B-1-1 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGESNOTE: The portion of the text affected by the changes is indicated by a vertical line in the outermargins of the page. Changes to illustrations are indicated by shaded or screened areas,or by miniature pointing of issue for original and changed pages 0.

2 15 June 2007 TOTAL NUMBER OF PAGES IN THIS MANUAL IS 774, CONSISTING OF THE FOLLOWING:Page*ChangePage*ChangePage* 0A .. 0i - 0xxiv 01-1 - 02-1 - 03-1 - 03-128 04-1 - 04-96 05-1 - 05-110 06-1 - 06-196 0 Glossary 1 - Glossary 0*Zero in this column indicates an original 33B-1-1 TABLE OF xixSAFETY SUMMARY .. xxi1 NONDESTRUCTIVE INSPECTION METHODS, GENERAL INFORMATION ..1-1 SECTION I NONDESTRUCTIVE INSPECTION (NDI) METHODS .. We Do NONDESTRUCTIVE INSPECTION (NDI) .. INSPECTION Data .. Management Programs .. for Using NDI Data .. for Gathering NDI II PERSONNEL TRAINING/QUALIFICATION/CERTIFICATION .. Training/Qualification/Certification .. Requirements .. Requirements .. for Special Task Certification and Recurring III REPORTING NEW OR IMPROVED NDI TECHNIQUES .. New/Improved NONDESTRUCTIVE INSPECTION Techniques .. for Reporting New and Improved Techniques.

3 Form for Updating Techniques .. Form 242 Entries ..1-6 SECTION IV NDI EQUIPMENT .. NDI Equipment (AIR FORCE Only) .. Procured NDI System Specific/Special Purpose Purchase V PROCESS for Controlling the Process .. of Process Control .. Control Documentation Requirements .. a Documentation Method .. Documentation Method ..1-12 SECTION VI LABORATORY INFORMATION .. Laboratory Information .. a NONDESTRUCTIVE INSPECTION Laboratory .. Requirements .. and Mechanical Identification ..1-152 LIQUID PENETRANT INSPECTION METHOD ..2-1 SECTION I LIQUID PENETRANT INSPECTION METHOD .. Capabilities of Liquid Penetrant INSPECTION .. to Liquid Penetrant INSPECTION .. of Liquid Penetrant INSPECTION .. Use Liquid Penetrant of Liquid Penetrant INSPECTION .. of Liquid Penetrant of Liquid Penetrant INSPECTION .. Penetrant INSPECTION Requirements.

4 Penetrant Classification and Processes .. of Penetrant Material .. of Penetrant Sensitivity .. Material II PRINCIPLES AND THEORY OF LIQUID PENETRANT and Theory of Liquid Penetrant INSPECTION .. of a of Penetrant Action .. Liquid Penetrant Enters Discontinuities .. and Principles of Penetrant Removal .. of Developer Action .. and Surface Conditions Affecting Penetrant INSPECTION .. and Soils .. of Surface Deformation, Wear, and Surface Roughness on Penetrant INSPECTION ..2-29 SECTION III LIQUID PENETRANT INSPECTION .. Equipment .. INSPECTION Equipment - General Purpose .. Parts INSPECTION Systems .. INSPECTION Systems .. Control Equipment ..2-35 SECTION IV LIQUID PENETRANT APPLICATION METHODS .. Method .. Penetrant Processes .. Preformed by NDI Personnel .. Application .. Limitations .. Dwell .. Washing/Rinsing Technique.

5 Of Developers .. After Penetrant of Parts Following Penetrant INSPECTION ..2-77 SECTION V INTERPRETATION OF LIQUID PENETRANT INSPECTION .. of Indications .. of Understanding the Interpretation Process .. Requirements .. Conditions .. Indications ..2-83 SECTION VI PROCESS CONTROL OF LIQUID PENETRANT Penetrant Process Control .. for Process Quality .. Test New Materials .. Test In-Use Materials .. of Material Work Center Process Control Intervals .. Control Equipment .. Control of New Materials .. In-Use Materials ..2-102 SECTION VII SPECIAL PURPOSE LIQUID PENETRANTS .. Purpose Liquid Penetrant .. Oxygen (LOX) Compatible Sulfur, Low Chlorine Penetrant Temperature Penetrant Materials .. Precipitation Penetrant Systems .. Fluorescence Method .. Penetrant .. Expansion Developers .. Developers ..2-120 SECTION VIII LIQUID PENETRANT INSPECTION Penetrant INSPECTION Safety.

6 Precautions .. Protection Equipment .. (Black Light) PARTICLE INSPECTION METHOD ..3-1 SECTION I MAGNETIC PARTICLE INSPECTION METHOD .. Capabilities of Magnetic Particle INSPECTION .. to Magnetic Particle INSPECTION (MPI) .. of Magnetic Particle INSPECTION .. Concept of Magnetic Particle INSPECTION ..3-1 SECTION II MAGNETIC PARTICLE PRINCIPLES AND and Theory of Magnetic Particle INSPECTION .. of Magnetization .. Terminology .. Field Used to Generate Magnetic Fields .. Material Characteristics ..3-10 SECTION III MAGNETIC PARTICLE INSPECTION EQUIPMENT .. Particle INSPECTION Equipment and Materials .. of Magnetic Particle INSPECTION Equipment .. of Magnetic Particle INSPECTION Equipment .. Equipment Purpose Strength Measurement Devices .. and Selecting Magnetic Particle INSPECTION Materials ..3-20 SECTION IV MAGNETIC PARTICLE INSPECTION APPLICATIONS.

7 Particle INSPECTION Application Methods .. Preparation .. Particle INSPECTION Techniques .. a Magnetizing Current .. Field .. Strength Measurement of Particle Application .. Fluorescent INSPECTION Magnetic Particle INSPECTION .. Magnetization Magnetization .. INSPECTION Cleaning .. Rubber INSPECTION ..3-63 SECTION V MAGNETIC PARTICLE INSPECTION INTERPRETATIONS .. Particle INSPECTION of Discontinuities and their of Terms .. Steps of INSPECTION .. of Discontinuities .. Indications .. and Elimination of Non-Relevant Indications .. of Recording MPI Indications ..3-103 SECTION VI PROCESS CONTROL OF MAGNETIC PARTICLE INSPECTION .. Particle Process and Scope .. of System Degradation .. of Process Control .. the Magnetic Particle Process .. Equipment Effectiveness .. Material Effectiveness .. Tests for Water Baths .. for Nonconformance Particle Process Checklist.

8 3-119 SECTION VII MAGNETIC PARTICLE INSPECTION EQUATIONS .. Particle Formulas .. Area .. Coil Current ..3-122 SECTION VIII MAGNETIC PARTICLE INSPECTION Particle Safety .. Precautions .. Matting .. Suspension Precautions .. Precautions .. Stocks .. (Black Light) of Aerosol Cans .. Rubber Precautions ..3-1274 EDDY CURRENT INSPECTION I EDDY CURRENT TESTING (ET) METHOD .. Capabilities of to ET .. of Eddy Current .. With Eddy Current .. of Eddy Current Method .. Affecting Eddy Current of Conductivity on Eddy Detection in Non-Ferromagnetic Materials .. Lag at Depth ..4-11 SECTION II EDDY CURRENT PRINCIPLES AND THEORY .. and Theory of and Processes ..4-13 SECTION III EDDY CURRENT EQUIPMENT TYPES .. of an ET System .. Current Subsystems .. of the Eddy Current Instrument .. Requirements .. Instrumentation Requirements.

9 Circuits and Eddy Current Systems .. Eddy Current Thickness Measurements .. and .. Ray Tube (CRT) Display .. Time Base Display .. Plane Eddy Current Test Equipment .. Testing Techniques .. Frequency Testing .. Eddy Current Testing .. Frequency Noise Testing of Ferromagnetic Materials .. on Titanium .. Aluminide .. Imaging (MOI).. of Advanced IV APPLICATION OF ET .. Response .. of Fastener Hole INSPECTION Equipment .. Compensation for Bolt-Hole INSPECTION .. Settings .. Hole to Edge Spacing .. and Holes Non-Removable Fasteners .. Selection .. for Nonremovable Fastener Holes .. and Rounded Corner .. Diagrams .. Selection .. Selection .. Reference Standards .. Procedure-Corrosion Detection .. Preparation .. Measurement of Conductivity .. of Aluminum Alloys .. Treatment Effects on Aluminum Conductivity.

10 In Aluminum Alloy Heat Treatment .. of Conductivity Measurement .. for Magnetic Materials .. of Variations in Material of Variations in Test Conditions .. Material .. Detection .. Selection .. Effects .. Compensation Methods .. of Crack Location on Detectability .. of Scanning Techniques on Detection .. Standards for Measurement .. of Total Metal Thickness ..4-71 SECTION V INTERPRETING EDDY CURRENT SIGNALS .. of Crack of Scan Rate and , Large Holes, and Cutouts .. for Measuring Conductivity Values ..4-79 SECTION VI EDDY CURRENT PROCESS CONTROL .. Process .. Test .. Test ..4-80 SECTION VII EDDY CURRENT EQUATIONS .. and Equations .. Factor .. of Penetration ( ).. Frequency, fg. and the Similarity Frequency .. Flaw Frequency for Setting Filters .. of Conductivity ..4-94 SECTION VIII EDDY CURRENT Safety.