Contents (continued) Paragraph Page
Page xviii
4-86............................... SPLICING USING LARGER DIAMETER REPLACEMENT TUBES
.4-67
FIGURE 4-40.SPLICING USING LARG ER DIAMETER REPLACEMENT TUBE 4-69
4-87.............................................................. REPAIRS AT BUILT-IN FUSELAGE FITTINGS
.4-70
FIGURE 4-41................... REPAIRS AT BUILT-IN FUSELAGE FITTINGS 4-71
4-88............................................................................................ ENGINE-MOUNT REPAIRS
.4-70
4-89................................................................BUILT-UP TUBULAR WING OR TAIL-SPARS
.4-72
FIGURE 4-42......... STREAMLINE TUBE SPLICE USING ROUND TUBE
(APPLICABLE TO LANDING GEAR)4-73
4-90....................................................WING-BRACE STRUTS AND TAIL-BRACE STRUTS
.4-72
FIGURE 4-43........ STREAMLINE TUBE SPLICE USING SPLIT SLEEVE (APPLICABLE TO WING AND TAIL SURFACE BRACE STRUTS AND OTHER MEMBERS) 4-74
4-91................................................................................................LANDING GEAR REPAIR
.4-72
FIGURE 4-44......... STREAMLINE TUBE SPLICE USING SPLIT INSERT
(APPLICABLE TO LANDING GEAR)4-75
FIGURE 4-45.STREAMLINE TUBE SPL ICE USING PLATES (APPLICABLE TO
LANDING GEAR)4-76
FIGURE 4-46.REPRESENTATI VE TYPES OF REPAIRABLE AXLE ASSEMBLIES 4-77 FIGURE 4-47.LANDING GEAR ASSEMBLIES THAT CANNOT BE REPAIRED BY WELDING 4-78
4-92...........................................................................REPAIRS TO WELDED ASSEMBLIES
.4-73
4-93..................................................................................STAINLESS STEEL STRUCTURE
.4-74
4-94.4-103. [RESERVED.]4-78
SECTION 6. WELDING AND BRAZING SAFETY
4-104GENERAL
.4-79
4-105..................................................................................FIRE AND EXPLOSION SAFETY
.4-79
4-106................................................................................................WELDING WORK AREA
.4-79
4-107.......................................................................................................FIRE PROTECTION
.4-79
4-108...............................................................................................PROTECTIVE APPAREL
.4-80
4-109.............................................................................................................FIRST-AID KITS
.4-80
4-110.4-128. [RESERVED.]4-80
Chapter 5. NonDestructive Inspection (Ndi) SECTION 1. GENERAL
Contents (continued) Paragraph Page
Page xix
5-1GENERAL
.5-1
5-2.............................................................................................APPROVED PROCEDURES
.5-1
5-3......................................................................................................................NDT LEVELS
.5-1
5-4...................................................... TRAINING, QUALIFICATION, AND CERTIFICATION
.5-2
5-5FLAWS
.5-2
5-6.......................................................................................SELECTING THE NDI METHOD
.5-5
TABLE 5-1. ADVANTAGES AND DI SADVANTAGES OF NDI METHODS 5-7
5-7................................................................................................ TYPES OF INSPECTIONS
.5-6
5-8.5-14. [RESERVED.]5-7
SECTION 2. VISUAL INSPECTION
5-15GENERAL
.5-9
5-16..............................................................................SIMPLE VISUAL INSPECTION AIDS
.5-9
5-17BORESCOPES
.5-10
FIGURE 5-1. ....................................... TYPICAL BORESCOPE DESIGNS 5-11
Contents (continued) Paragraph Page
Page xx
5-18........................................................................... VISUAL INSPECTION PROCEDURES
.5-10
FIGURE 5-2...........USING A FLASH LIGHT TO INSPECT FOR CRACKS 5-13
5-19.5-24. [RESERVED.]5-13
SECTION 3. EDDY CURRENT INSPECTION
5-25......................................................................................EDDY CURRENT INSPECTION
.5-15
FIGURE 5-3. ....................................GENERATING AN EDDY CURRENT 5-15 FIGURE 5-4. .......................................DETECTING AN EDDY CURRENT 5-15 FIGURE 5-5. ..................................... TYPICAL INSTRUMENT DISPLAYS 5-16
5-26........................................................................ EDDY CURRENT COILS AND PROBES
.5-15
5-27........................................... FIELD APPLICATION OF EDDY CURRENT INSPECTION
.5-15
5-28................................................................................................. SURFACE INSPECTION
.5-16
FIGURE 5-6. .............................................. TYPICAL SURFACE CRACKS 5-16
5-29..........................................................................................SUBSURFACE INSPECTION
.5-17
FIGURE 5-7. .......................................TYPICAL SUBSURFACE CRACKS 5-18
5-30............................................................................................CORROSION INSPECTION
.5-17
FIGURE 5-8. ................................TYPICAL STRUCTURAL CORROSION 5-18
5-31................................ESTABLISHING EDDY CURRENT INSPECTION PROCEDURES
.5-17
5-32.5-39. [RESERVED.]5-18
SECTION 4. MAGNETIC PARTICLE INSPECTION
5-40GENERAL
.5-19
5-41........................................................................................PRINCIPLES OF OPERATION
.5-19
FIGURE 5-9. ........................................... MAGNETIC FIELD DISRUPTED 5-19 FIGURE 5-10.CRACK DETECTION BY MAGNETIC PARTICLE INSPECTION 5-19
5-42APPLICATIONS
.5-20
5-43...................................................................ELECTRICAL MAGNETIZING EQUIPMENT
.5-20
5-44....................................... MATERIALS USED IN MAGNETIC PARTICLE INSPECTION
.5-20
TABLE 5-2... LISTING OF COMMONLY ACCEPTED STANDARDS AND ................SPECIFICATIONS FOR MA GNETIC PARTICLE INSPECTION 5-21
Contents (continued) Paragraph Page
Page xxi
5-45....................................................................................... PREPARATION OF SURFACE
.5-22
5-46........................................................................................METHODS OF EXAMINATION
.5-22
5-47.................................................................. APPLICATION OF MAGNETIC PARTICLES
.5-22
5-48MAGNETIZATION
.5-23
FIGURE 5-11. ............................................ CIRCULAR MAGNETIZATION 5-23 FIGURE 5-12. .................................... LONGITUDINAL MAGNETIZATION 5-24
5-49.....................................................................DETERMINATION OF FIELD STRENGTH
.5-25
5-50........................................................................SPECIAL EXAMINATION TECHNIQUES
.5-25
5-51......................................DEMAGNETIZATION AND POST-EXAMINATION CLEANING
.5-27
5-52.5-59. [RESERVED.]5-28
SECTION 5. PENETRANT INSPECTION
5-60GENERAL
.5-29
FIGURE 5- 13.......................... PENETRANT AND DEVELOPER ACTION 5-30
5-61........................... EQUIPMENT USED IN THE PENETRANT INSPECTION PROCESS
.5-29
TABLE 5-3.CLASSIFICATION OF PENETRANT INSPECTION MATERIALS
COVERED BY MIL-I-25135E5-30
Contents (continued) Paragraph Page
Page xxii
5-62.......................................BASIC STEPS TO PERFORM PENETRATION INSPECTION
.5-29
TABLE 5-4.. FLUORESCENT AND VI SIBLE PENETRANT INSPECTION ........................GENERAL PR OCESSING PROCEDURES FLOWSHEET 5-31 TABLE 5-5.PRE-CLEANING METH ODS FOR PENETRANT INSPECTION 5-32
5-63CLEANERS
.5-33
5-64. TECHNICAL STANDARDS5-34
TABLE 5-6... LISTING OF COMMONLY ACCEPTED STANDARDS AND
SPECIFICATIONS FOR ........................................................................PENET RANT INSPECTION 5-35
5-65.5-72. [Reserved.]5-35
SECTION 6. RADIOGRAPHY (X-RAY) INSPECTION
5-73GENERAL
.5-37
FIGURE 5-14RADIOGRAPHY
5-38
5-74LIMITATIONS
.5-37
5-75..................................................................................FILM OR PAPER RADIOGRAPHY
.5-37
5-76...........................................................................................REAL-TIME RADIOGRAPHY
.5-37
5-77.............ADVANTAGE OF REAL-TIME RADIOGRAPHY OVER FILM RADIOGRAPHY
.5-37
5-78.................................................................................COMPUTED TOMOGRAPHY (CT)
.5-37
5-79..............................................................................................USES OF RADIOGRAPHY
.5-38
5-80...............................................................COMPARISON WITH OTHER NDI METHODS
.5-38
5-81FLAWS
.5-39
5-82........................................................................................................ FIELD INSPECTION
.5-39
5-83SAFETY
.5-39
5-84.5-88. [RESERVED.]5-39
SECTION 7. ULTRASONIC INSPECTION
5-89GENERAL
.5-41
FIGURE 5- 15ULTRASOUND
5-42
5-90.....................................................................................................SOUND REFLECTION
.5-41
5-91..................................................................ULTRASONIC INSPECTION TECHNIQUES
.5-41
FIGURE 5-16.PULSE-ECHO AND T HROUGH-TRANSMISSION ULTRASONIC
INSPECTION TECHNIQUES5-42
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Page xxiii
5-92..........................................................................................................FLAW DETECTION
.5-41
5-93........................................................................................................ BASIC EQUIPMENT
.5-41
FIGURE 5-17.TYPICAL PORTABLE ULTRASONIC INSPECTION INSTRUMENT 5-43 FIGURE 5-18.................EXAMPLE OF POSITION FIXTURE AND SHOE 5-44 FIGURE 5-19.EXAMPLE OF THE U SE IF A TRANSDUCER POSITIONING FIXTURE 5-44 FIGURE 5-20........EXAMPLE OF A TYPICAL REFERENCE STANDARD 5-44
5-94................................................................... INSPECTION OF BONDED STRUCTURES
.5-43
FIGURE 5-21.EXAMPLES OF BONDED STRUCTURE CONFIGURATIONS
AND SUGGESTED INSPECTION COVERAGE5-47
TABLE 5-7........ ACCEPTABLE UL TRASONIC INSPECTION METHODS
ASSOCIATED WITH THE EXAMPLE BONDED STRUCTURE CONFIGURATIONS SHOWN IN FIGURE 5-
21. 5-48 TABLE 5-8.ULTRASONIC INSPECTION METHODS FOR BONDED STRUCTURES 5-49
5-95................................................................................... BOND TESTING INSTRUMENTS
.5-46
5-96..................................................................................... THICKNESS MEASUREMENTS
.5-50
5-97................................................................................................................LEAK TESTING
.5-50
5-98.5-104. [RESERVED.]5-51
Contents (continued) Paragraph Page
Page xxiv SECTION 8. TAP TESTING
5-105GENERAL
.5-53
FIGURE 5-22. ................................SAMPLE OF SPECIAL TAP HAMMER 5-53
5-106.5-111. [RESERVED.]5-53
SECTION 9. ACOUSTIC-EMISSION
5-112GENERAL
.5-53
5-113APPLICATIONS
.5-54
5-114.5-119. [RESERVED.]5-54
SECTION 10. THERMOGRAPHY
5-120GENERAL
.5-54
5-121.5-126. [RESERVED.]5-54
SECTION 11. HOLOGRAPHY
5-127GENERAL
.5-54
5-128.5-133. [RESERVED.]5-54
SECTION 12. SHEAROGRAPHY
5-134GENERAL
.5-55
5-135.5-140. [RESERVED.]5-55
Chapter 6. Corrosion, Inspection & Protection SECTION 1. GENERAL
6-1GENERAL
.6-1
FIGURE 6-1.SIMPLIFIED CORRO SION CELL SHOWING CONDITIONS
WHICH MUST EXIST FOR
ELECTROCHEMICA L CORROSION6-2
FIGURE 6-2. ELIMINATION OF CORROSION BY APPLICATION OF AN
ORGANIC FILM TO METAL SURFACE6-2
6-2......................................................................... FACTORS INFLUENCING CORROSION
.6-1
6-3....................................................................................COMMON CORROSIVE AGENTS
.6-3
6-4MICRO-ORGANISMS
.6-3
6-5.6-10. [RESERVED.]6-4
SECTION 2. TYPES OF CORROSION
6-11GENERAL
.6-5
FIGURE 6- 3........................................................... CORROSION ATTACK 6-5
6-12...............................................................................GENERAL SURFACE CORROSION
.6-5
Contents (continued) Paragraph Page
Page xxv FIGURE 6-4. .....................................GENERAL SURFACE CORROSION 6-5
6-13.................................................................................................... PITTING CORROSION
.6-5
FIGURE 6-5(A). PITTING CORRO SION (EXTERNAL VIEW)6-5
FIGURE 6-5(B). PITTING CORRO SION (MAGNIFIED CROSS SECTION) 6-5
Contents (continued) Paragraph Page
Page xxvi
6-14.........................................................................CONCENTRATION CELL CORROSION
.6-6
FIGURE 6-6. ...............................CONCENTRATION CELL CORROSION 6-6
6-15............................................................................................... ACTIVE-PASSIVE CELLS
.6-6
FIGURE 6-7.........................................................ACTIVE-PASSIVE CELL 6-7
6-16................................................................................................. FILIFORM CORROSION
.6-7
FIGURE 6- 8........................................................ FILIFORM CORROSION 6-7
6-17................................................................................... INTERGRANULAR CORROSION
.6-7
FIGURE 6-9. INTERGRANULAR CORROSION OF 7050-T6 ALUMINUM
ADJACENT TO STEEL FASTENER6-8
6-18.......................................................................................... EXFOLIATION CORROSION
.6-7
FIGURE 6- 10............................................... EXFOLIATION CORROSION 6-8
6-19................................................................................................GALVANIC CORROSION
.6-8
FIGURE 6-11.GALVANIC CORROSION OF MAGNESIUM ADJACENT TO
STEEL FASTENER6-9
6-20................................................................................STRESS CORROSION CRACKING
.6-8
FIGURE 6-12. ....................................STRESS CORROSION CRACKING 6-9
6-21...................................................................................................FATIGUE CORROSION
.6-9
6-22................................................................................................ FRETTING CORROSION
.6-10
FIGURE 6- 13..................................................... FRETTING CORROSION 6-10
6-23.6-28. [RESERVED.]6-10
SECTION 3. CORROSION PROTECTION MEASURES FOR BASIC MATERIALS
6-29GENERAL
.6-11
6-30....................................................................ANODIZING AND RELATED PROCESSES
.6-11
6-31PLATING
.6-11
6-32....................................................................................PHOSPHATE RUST-PROOFING
.6-11
6-33....................................................................................CHROME-PICKLE TREATMENT
.6-11
6-34..........................................................................................DICHROMATE TREATMENT
.6-11
6-35......................................................................... STANNATE IMMERSION TREATMENT
.6-11
6-36...........................................................................GALVANIC ANODIZING TREATMENT
.6-12
Contents (continued) Paragraph Page
Page xxvii
6-37CLADDING
.6-12
6-38..........................................................................................................METAL SPRAYING
.6-12
6-39SHOT-PEENING
.6-12
6-40.....................................................................................................ORGANIC COATINGS
.6-12
6-41........................................................................................................... DOPE PROOFING
.6-12
6-42........................................................................................................... TUBE INTERIORS
.6-12
6-43.6-49. [RESERVED.]6-12
SECTION 4. CORROSION PREVENTIVE MAINTENANCE
6-50........................................................................................ GUIDELINES: ALL AIRCRAFT
.6-13
6-51......................................GUIDELINES: AIRCRAFT OPERATING OVER SALT WATER
.6-13
6-52.6-62. [RESERVED.]6-14
SECTION 5. VISUAL CORROSION INSPECTION GUIDE FOR AIRCRAFT
6-63GENERAL
.6-15
6-64................................................................................................ EXHAUST TRAIL AREAS
.6-15
6-65................................BATTERY COMPARTMENTS AND BATTERY VENT OPENINGS
.6-15
6-66.........................................................................................LAVATORIES AND GALLEYS
.6-15
6-67..................................................................................................................BILGE AREAS
.6-15
6-68..........................................................................WHEEL WELLS AND LANDING GEAR
.6-15
Contents (continued) Paragraph Page
Page xxviii
6-69................................................................................................EXTERNAL SKIN AREAS
.6-15
6-70.....................................................................................WATER ENTRAPMENT AREAS
.6-16
6-71.............................................................................................ENGINE FRONTAL AREAS
.6-16
6-72................................................................ELECTRONIC PACKAGE COMPARTMENTS
.6-16
6-73......................................................................................FLEXIBLE HOSE ASSEMBLIES
.6-16
6-74.......................................................................................................SANDWICH PANELS
.6-16
6-75.........................................................................................................CONTROL CABLES
.6-16
6-76.................................................................................................INTEGRAL FUEL CELLS
.6-16
6-77........................................................................................ ELECTRICAL CONNECTORS
.6-16
6-78.6-88. [RESERVED.]6-16
SECTION 6. CORROSION REMOVAL PROCEDURES
6-89GENERAL
.6-17
6-90................................................................................................ SAFETY PRECAUTIONS
.6-17
6-91..........................................................CORROSION CONTROL WORK PROCEDURES
.6-18
6-92.6-112. [RESERVED.]6-19
SECTION 7. BASIC CORROSION REMOVAL TECHNIQUES
6-113GENERAL
.6-21
6-114................................................................................. PREPARATIONS FOR REWORK
.6-21
6-115........................................................... FAIRING OR BLENDING REWORKED AREAS
.6-21
TABLE 6-1........................... ABRASIVES FOR CORROSION REMOVAL 6-22 FIGURE 6-14...... TYPICAL EXAMPLE OF ACCEPTABLE CLEANUP OF
CORROSION PITS6-23
FIGURE 6-15.BLENDOUT OF CORROSION AS A SINGLE DEPRESSION 6-24 FIGURE 6-16.BLENDOUT OF MULTIPLE PITS IN A CORRODED AREA 6-24
6-116......................................................................CORROSION REMOVAL BY BLASTING
.6-22
6-117...........................................................CLEANERS, POLISHES, AND BRIGHTENERS
.6-22
6-118.................................................................................................STANDARD METHODS
.6-23
6-119.6-131. [RESERVED.]6-24
SECTION 8. ALUMINUM AND ALUMINUM ALLOYS
Contents (continued) Paragraph Page
Page xxix
6-132GENERAL
.6-25
6-133...................................................SPECIAL TREATMENT OF ANODIZED SURFACES
.6-25
6-134.........................................................REPAIR OF ALUMINUM ALLOY SHEET METAL
.6-25
6-135.CORROSION REMOVAL AROUND COUNTERSUNK FASTENERS IN ALUMINUM ALLOY
.6-26
6-136.EXAMPLES OF REMOVING CORROSION FROM ALUMINUM AND ALUMINUM ALLOYS
.6-26
6-137.6-147. [RESERVED.]6-28
SECTION 9. MAGNESIUM AND MAGNESIUM ALLOYS
6-148GENERAL
.6-29
6.149................... TREATMENT OF WROUGHT MAGNESIUM SHEETS AND FORGINGS
.6-29
6.150.REPAIR OF MAGNESIUM SHEET METAL AFTER EXTENSIVE CORROSION REMOVAL
.6-29
6.151...............................................IN-PLACE TREATMENT OF MAGNESIUM CASTINGS
.6-30
6.152................................. EXAMPLE OF REMOVING CORROSION FROM MAGNESIUM
.6-30
6-153.6-163. [RESERVED.]6-33