Spencer Parade, Nosmampton NDT iui? aaa United Kingaom etoara oye Tes +44(0)100¢250.050 Fox sadeo04 28 a8 mire E-mai: pon@binat org elias PCNIGEN Appendix A2 Issue 4 dated August 2003 (for implementation on 1 January 2004). QUALIFICATION AND CERTIFICATION OF NDT PERSONNEL FOR ULTRASONIC TESTING OF AEROSPACE MATERIALS COMPONENTS & STRUCTURE This Appendix to PCN General Requirements for Qualification and Certification of NOT Personnel covers the specific requirements for PCN certification of personnel engaged in Ultrasonic Non- Destructive Testing of Aetospace Materials, Components and Stuctures manufactured trom conventional and composite metallic or nommetalic bonded sandwich materials Certification issued as a result of success in an examination defined herein complies with European standard EN 473, international standard ISO 9712, and may be used by employers of NDT personnel to satisfy the qualification requirements of European Standard EN 4179. ‘Any person requiring information concerning the content of PCN documents should address queries to the PCN Scheme Manager at the above address. ASSOCIATED DOCUMENTS: Appendix AO Qualifcation and certification of NDT personnel for the Aerospace industry mult-sector. Appendix A2.2 Syllabus for PCN Examination of Personnel engaged in Ultrasonic Testing of Aerospace Materials Components ang Structures, ‘Appendix A2.3 Example questions for PCN Examination of Personnel engaged in Ultrasonic Testing of Aerospace Materials Components and Structures, CONTENTS: 1, SCOPE 2. EXAMINATION CONTENT. 3, CERTIFICATION AVAILABLE 4, SUPPLEMENTARY EXAMINATIONS 5, RENEWAL AND RECERTIFICATION ‘The British Institute of Non-Destructive Testing is an accredited certification body tesng pascal and cual management eyes assesment and catenin (yx) ‘against eiteria set out in international and European standards through the PCN Conification Scheme,1. SCOPE Requirements contained in this document are supplementary to and must be read in conjunction with those contained in the current edition of PCN General Requirements for the Qualification and Cerlfication of NOT Personnel. This Appendix amplifies the provisions of PCNIGEN only where necessary. In the event of any conflict, the PCN Aerospace Specific Requirements shal prevall 2. EXAMINATION CONTENT 2A Level 2 PCN aerospace certification is available to cover aerospace materials and components, and aircraft structures. PCN does not currently offer certification for level 1 personnel carrying out NOT in the aerospace industy sector. For level 2 candidates, the content of the practical examination will reflect the certification sought (see Clause 3). The examination will comprise: 2.1.1 General knowledge of the Ultrasonic NDT method. Forty muti allowed: 60 minutes; pass mark 70%, choice questions. Time 2.4.2 Sector specific application of the Ultrasonic NOT method to aerospace products. The examination will compnse of thirty multiple choice questions covering standards, codes and specifications, safety precautions in the aerospace environment, basic production processes and associated defects, and defects occurring in service. Time allowed: 60 minutes; pass mark 70% 2.1.8 Sector Specific Practical examination comprising |) calibration and functional checking of Ultrasonic test equipment, li) testing three samples appropriate to the category of certification sought (see Clause 3.2) Using @ range of Utasonic test equipment and techniques, reporting the results in @ prescribed manner in accordance with the code, specification or standard provided (this will Include any calculations necessary for inspection sensitivities), i) preparation of a detailed NDT instruction providing written step by step information on the testing of one of the above samples (selected by the examiner) to a provided procedure, code, standard or specification, and to prove the instruction by application. ‘The total time allowed for the practical part is 8 hours. The minimum pass mark for the practical partis 70% per sample tested and 70% for the NDT instruction (failure to detect and report a reportable discontinuity in any one sample, oF failure to produce an acceptable NOT instruction, will result in {failure ofthis examination part), 22 Level 3 Except where exemptions apply (refer to PCN General Requirements), all level 3 candidates will be Fequired to attempt an examination comprised af the following parts: 22.1 A Basic Examination (information on the time allowed and pass mark is given in the current edition of PCN General Requirements), comprising: 1) Thirty muitiple choice questions covering materials technology and science, including typical defects in a range of products including castings, welds and wrought products. 42) Ten multiple choice questions on the content of the current edition of PCN General Requirements. for Certification of Personnel engaged in the application of non destructive testing (a copy of which willbe srovided for use in the examination). 8) Sixty level 2 multiple choice questions on the general theory of four NDT methods. The examination will include fifteen questions on the NOT method in which the candidate is presently seeking certification, and a further fifeen on each of three other methods selected by the candidate (NB. at least one of the four methods examined ‘must be a volumetric methed). PCNIGEN Aependlc A2 2ota Issue 4 dated 1 August 2003,2.2.2 Main Method Examination C1) Thirty multiple choice questions covering the general theory of the Uttrasonic testing method. 2) Twenty multiple choice questions covering the application of the Ultrasonic NDT method in the aerospace industry sector, including the applicable codes, standards and specifications (the candidate will be provided with any relevant code, standard or specification). C3) An open book examination in which the candidate will be required to produce a Comprehensive Ultrasonic test procedure embodying an NOT instruction for a specific ‘aerospace product to a provided specification, standard or code, 2.23 Level 2 Sector Specific Practical. Applicable to level 3 candidates who do not hold level 2 Certification acceptable to PCN for Ultrasonic testing of aerospace products. Such candidates will be required to successfully complete the level 2 practical examination for materials components and structures before proceeding tothe level 3 main method examination parts. 3. CERTIFICATION AVAILABLE, 3.1 Level 2 Ultrasonic Testing of: 3.1.4 aerospace materials and components (the practical examination will comprise the testing of three specimens, selected by the examiner, representative of aerospace components). 3.12 aerospace materials components and structures (the practical examination will comprise the testing of three specimens, selected by the examiner, representative of aerospace components and structure), 3.2 Level 3 Ultrasonic Testing (Aerospace materials components and structures) 4, SUPPLEMENTARY EXAMINATIONS. 4.1 Existing PCN level 2 (aerospace) materials and components certificate hlders may attempt a supplementary examination to include aerospace structures. The supplementary examination content will be as follows: 4.1.1 A sector specific practical examination comprising 2) calibration and functional checking of Ultrasonic test equipment, testing two aerospace structure samples, and ) reporting the results in @ prescrited manner in accordance with the code, specication or standard provided (this wil include any calculations necessary for inspection sensitivities). Time allowed: 4 hours. 42 The grading of supplementary examinations, and the retesting of failed supplementary examinations, wil be as specified in the current edition of PCN General Requirements for the ‘Qualification and Certifcation of Non-Destructive Testing Personne’. PONIGEN Appendix A2 3ot4 Issue 4 dated 1 August 20035, RENEWAL AND RECERTIFICATION 5.1 The general rules for level 2 renewal and recertification are fully described in PCN document (CP16, and the rules for level 3 recertification are detailed in PCN document CP17, 5.2 Level 2 certificate holders seeking recertification will be required to comply with CP16 criteria and attempt a Sector Specific Practical examination comprising |) calibration and functional checking of Ultrasonic test equipment. i) testing two samples of aerospace products selected by the examiner appropriate to the NOT method and category of certification held, reporting the results in a prescribed manner in accordance with the code, specification or standard provided (this will include any calculations necessary for inspection sensitivities). Wi) preparation of a detailed NOT instruction providing written step by step information on the {esting of one of the above samples (selected by the examiner) to a provided procedure, ‘code, standard or specification 5.2.1. The total time allowed for the level 2 receriffcation examination is 6 hours. The minimum pass mark forthe practical partis 70% per sample tested and 70% for the NDT instruction failure to detect land report a reportable discontinuity in any one sample, or failure to produce an acceptable NDT instruction, will result in failure ofthis examination per), PCNIGEN Appenaix AZ 4ot4 Issue 4 dated 1 August 2003,Certification Services Division 4 Spencer Parade, Northampton NDT NN SAA, United Kingdom = Te +44(0)1604250.056 rca PCNIGEN Appendix A2.2 SYLLABUS COVERING THE EXAMINATION OF NDT PERSONNEL FOR ULTRASONIC TESTING OF AEROSPACE MATERIALS COMPONENTS & STRUCTURE (Mi ‘This Appendix to PCN General Requirements for Qualification and Gertfcation of NDT Personnel covers the examination eyllabus for PCN certification of personnel engaged in Ultrasonic Non- Destructive Testing of Aerospace Materials, Components and Structures. Certification issued as a result of success in an examination defined herein complies with Europe standard EN 473, international standard 1SO 9712, and may be used by employers of NOT personnel to satisfy the quaification requirements of European Standard EN 4179. ‘Any person requiring information concerning the content of PCN documents should address queries to the PCN Scheme Manager at the above address, ASSOCIATED DOCUMENTS: ‘Appendix AO Qualifcation and certineation of NDT personnel for the Aerospace industry mult-sector. ‘Appendix A2.1 ‘Quatitcation and certitcation of NOT personnel for Ultrasonic Testing of Aerospace Materials, Components and Structures. ‘Appendix 2.3 Example questions for PCN Examination of Personnel engaged in Ultrasonic Testing of Aerospace Materials Components and Structures, CONTENTS LEVEL 1 SYLLABUS LEVEL 2 SYLLABUS REFERENCE LITERATURE offering personnel and qualty management systems assessment and corticaton ‘against ereria set out in intemavonal and European standards tough the PCN ‘The Britsh Institute of Non-Destructive Testing is an accreted certcation body S Certiication Scheme,LEVEL 1 SYLLABUS [Although there are currently no level 1 examinations available in the aerospace sector, the level 2 ‘examination syllabus includes that for level 1 and THE LEVEL 1 SYLLABUS IS THEREFORE INCLUDED HEREIN since the depth of knowledge required increases from level 1 through level 2 to level 3. 1.1 General Theory Introduction - essential features of ultrasonic testing. Generation of ultrasonic waves. Electromagnetic transducers (piezo dectric, magnetostrictive and electrodynamic). Properties of the transducer (nominal and working frequency, bandwidth). Effect of different transducer materials Wave properties - types of wave, vibration, waves, sound waves, continuous wave, pulse. Units, relationship between frequency, velocity and wavelength. Principles of reflection and transmission of sound waves at perpendicular incidence. Erfect of coupling ‘media on transmission. Acoustic impedance. Principles of reflection and refraction of sound vaves at inclined incidence. Factors affecting angles of reflection, refraction and mode conversion Effect of reflector on echo response. Sound field - influence of frequency, sound velocity and size of transducer. Estimate of near field, far field and beam divergence. Influence of properties of test object on sound propagation, sound velocity and attenuation. Definition ‘and use of decibel Equipment construction and mode of operation. Block diagram of an ultrasonic instrument with single and double transducer, controls and functions of ultrasonic instrument. Signal presentation -A, B, C scans, Types of probe - normal beam, single and twin crystal, angle beam. Construction and mode of operation. Probe index. Beam angle. Squint. ‘Scanning techniques - manual, semi-automatic, automatic, Testing Techniques (basic principles): Pulse-echo technique, measured values (transmit time, echo amplitude), advantages and limitations; Contact scanning - couplant, protective layer, Gap scanning Immersion’ testing; Through-transmission technique, measured value (intensity), advantages and limitations. Application of compression and shear waves. Calibration of Testing Systems: Timebase calibration - normal, single and twin crystal and angle beam probes. Calibration blocks and reference blocks. Calibration checks. Erfect of different sound velocities in Calibration block and test piece Measurement of wall thickness and flaw position using normal and angle beam probes, ‘Sensitivity setting - simple methods, BWE, DAC. Sensitivity and signal to noise ratio; sensitivity and pulse duration, Effect of surface finish, geometry and attenuation in specimen 41.2 Sector Specific Theory Detectablty of Defects; advantages and limitations of the test method with regard to defect detection, Factors Affecting the Performance of the Ultrasonic Test. Mechanical properties of the material, attenuation. Geometry of the specimen. Surface condition Codes of Practice and Standards ‘See essential reading list. Conducting and Recording the Test Routine calibration of equipment, Procedure to be adopted to carry out the test. Information to be recorded on the report. Flaw assessment, sizing techniques and reporting PCNIGEN Appendix A2 207 Issue 4 datod 1 August 2003LEVEL 2 SYLLABUS 24 General Theory Allof the general theory for level 1 and, in addition: 2.1.1 Physical Principles of Ultrasonic Testing Behaviour of sound wave for perpendicular incidence. Acoustic impedance. Reflection and transmission factors. Calculations of reflected and transmitted energy. Behaviour of sound wave for inclined incidence. Snel's Law concerning reflection, refraction and ‘mode conversion. Critical angles. Calculations, Interpretation and prediction of boundary echoes. Time base position of mode converted echoes under known conditions, Influence on sound waves of reflector size (reflection, scatter refraction, interference. Reflection at defined reflectors. Laws concerning distance and size of backwall echo, side drilled hole and disc reflectors. Comparison with real flaws. ‘Souns field. Calculation and estimation of rear field, far field and beam spread, Influence of properties of specimen on sound propagation, attenuation, cause, effect and measurement, attenuation coefficient. Surface shape and condition. Sound velocity, cause, effect and measurement . 2.1.2 Equipment Probe construction and mode of operation. Special probes, double crystal angle probes, focused probes, probes with diferent damping, Measurement of resolving power of angle probes. Correlation between resolution, frequency penetrating power and damping, ‘Amplifier characteristics, broad and narrow band, logarithmic, saturation, linearity, suppression, DAC correction, ‘Signal presentation. Deeper knowledge of automatic test systems. 2.2 Sector Specific Theory 2.2.1 Calibration of Testing Systems ‘Timebase calipration - projected distance, shortened projected distance. Thin wall, curved surfaces, effect of afferent materials. Construction of reference lines and calibration of sensitivity with reference to backwall echo, side drilled hole, at bottomed hole. Reference block and DGS methods. Measurement of the differences for surface condition and attenuation between test piece and reference biock. Correction for transfer (coupling, attenuation) correction for attenuation depending on, path length, correction for near surface defects, 2.2.2 Detectabilly of Defects ‘Advantages and limitations of the test method with regard to defect detection. Tandem techniques, transmission techniques, causes of spurious indications and other signals not associated with defects, selection of method for accurate sizing of defects. Types of signal from typical flaws. Errors in defect size/measurement. Influence on techniques of geomety, size, surface condition, metal composition, structure. influence of surface coatings, heat treatments and repairs. 2.2.3 Factors Affecting the Performance of the Ultrasonic Test Relationship between properties of the material, conation, attenvation and sound velocity, Testing of ‘materials with differing attenuation characteristics, including aistenilic steels. Selection of probe type, frequency and angle. Preparation of test surface. Selection of couplant and method PONIGEN Appendix A2 3017 Issue 4 dated 1 August 2003Influence of defect type, position and orientation on detection, eg. size, geometry, distance from surface, orientation, reflectivity and opacity 2.2.4 Codes of Practice and Standards See essential reading list. Establishing of testing instructions considering application, equipment, technique, probes, calibration, ‘operation of test, recording of test results. 2.2.5 Conducting and Recording the Test Procedure to be adopted to carry out the test. Information to be recorded on the report including sensitivity levels. Flaw assessment and reporting 2.26 Interpretation of Test Results Interpretation of test results to acceptance standards. 23, Secor Specie Aerospace Product Technology Theory ‘The depth of knowledge required will be such that the candidate will be capable of understanding the description of potential defects and their likely locations @s specified in NOT instructions and procedures; describing unambiguously in NOT reports the nature and location of what has been found such that the non-NDT engineer can gain an accurate appreciation of the condition of the inspected area. 2.3.1, Aerospace Materials and Components Candidates will be required to demonste detects and heat treatments, 2a basic understanding of production methods, associated Basic Casting Production Methods: Sand casting; die casting; investment casting Basic defects associated with cast products and their appearance: shrinkage; sinks; cold shuts Porosity; laps; hot tears; cracks. ‘Wrought products forming processes: cold rolling, open forging and press forging; closed die forging: extrusion, Defects associated with wrought product forming processes and their appearance: rolling defects forging bursts; laps; seams; cracks Heat treatment: annealing; normalising; es relieving 2.3.2 Aerospace Material Components and Structures Allof the above, and in addition, candidates will be required to demonstrate a basic understanding of ‘assembly and fastening technology, and defects associated with aerospace structure. Assembly of structure; knowledge of terms: primary and secondary structure; spars; ribs; frames; longerons: stringers; skin; multilayer assembly, composite assemblies. Fastening methods; knowledge of terms: threaded fasteners; rivets; bonding; brazing and welding Knowledge of terms, origins, nature and appearance of defects related to structures: fatigue cracking: stress corrosion cracking; corrosion ~ intergranular, exfoliation, surface or pitting, differential meta, and fretting, ‘The effects of corrosive substances on aircraft materials, eg. mercury Foreign object damage (FOD) and loose artces. PCNIGEN Appendix A2 4007 Issue 4 dated 1 August 2003Level 3 personnel are expected to be competent to assume the responsibilies of management of an industrial NOT facility. The PCN level 3 examination will therefore evaluate the candidate's knowledge of the folowing: Allocation of staff with appropriate certification according to customer's requirements. Supervision and maintenance of subordinate's certification and recerification documents and records, Compilation of records of equipment performance, repairs and maintenance; the work done and results achieved by supervised staff. The review of reports of work done by subordinates, its periodic validation, and the endorsement of routine reports Review of current practices, equipment, techniques and instructions, Maintenance of standards and {ext book libraries, Safe working practices end current legislation, Candidates will be required to be familiar with all the content of the theoretical and practical syllabi for level 2 and, in adaition 3.1.1 Alternative methods of data presentation ‘of which current examples include 8, C and O scan systems, and Time of Flight Diffraction (TOFD), ‘and methods of digital data-processing 3.1.2 Alternative probe arrangements ‘The purpose, construction and performance of twin crystal probes. Special arrays for detection of near surface defects, Probes with focused crystals, Probes with wide band frequency reception, The effective range of the above probes, comparative sensitivity to given reflectors and establishment of principal characteristics of beam spread, distance amplitude response curves and sensitivity settings fo achieve standard reflector equivalents 3.2. General Theory at Level 2 of Other NDT Methods The level 3 candidate is required to have a knowledge of level 2 general theory, including the limitations and applications ofthe principal and alternative methods of NDT. The examination syllabi are detailed in various documents obtainable from PCN. In detail, the level 3 candidate wil be required to demonstrate a knowledge of the general theory syllabus for PCN Ultrascnic Tester Level 2. and three other NDT methods chosen by the candidate from: PCN Radiographic Tester Level 2 (which may include the interpretation of radiographs to a code or detect acceptance standard), PCN Magnetic Particle Tester Level 2, PCN Penetrant Tester Level 2, and PCN Eddy Current Tester Level 2. 3.3 Knowledge of PCN Requirements {A thorough understanding of the requ detailed in PCNIGEN 3.4 Sector Specific Theory _ {lof the combined syllabus for PCN Ultrasonic Tester (Aerospace) Level 2, and in addition: 3.4.1 Flaw sizing systems ments for certification of all levels of NOT personnel as Knowledge of the currently used systems for defect sizing dependent upon geometry and material properties. The application of the systems for cross-sectional defect dimensions and for length of defects, PCNIGEN Appendbs AZ S07 Issue 4 dated 1 Augus! 20033.4.2 Flaw recording systems Knowledge of current systems for flaw recording. Recording echo height comparisons from actual efects and their equivalent reflectors from the test block used. 3.43 Sensiivily Methods of setting sensitivity for normal probes. Methods of setting sensitivity for angle probes to ‘bain ‘grain interference lever (or'grass’) and the recording of the equivalent calibration block echoes, and comparison with a standard calibration block Methods of setting sensitvty using predetermined calibration block echoes and making allowances for transfer loss and attenuation in the material 3.44 Accuracy and Limitation [A thorough knowledge of the effective range of all types of probe beams, both of maximum and ‘minimum path distances. Determination of the repeatabllty and accuracy of the cross section of simulated defects and of their length. Tabulation of the results achieved 3.4.5 Codes for Testing and Flaw Acceptance Limits Familiarity with the criteria in codes and standards covering the application of ultrasonics in the ‘aerospace sector. An understanding of the way in which these are applied in practice. 535 Materials Tectnology and Science ‘The level 3 examination will require the candidate to have a technical knowledge in materials science land technology. including production and in-service defects in a wide range of products, including castings, welds and wrought products Candidates wil be required to produce a writen procedure forthe inspection of a specified component to a provided code or standard, PCN publishes a document, reference CP25, for information and for se by candidates in this open book examination. NOTE: Codes and standards of other national (or international) origins may be proposed by candidates, if appropriate to their job responsibltes, for use in this examination module. Candidates should notity the test centre oftheir choice on the enrolment form and will be permitted to bring a copy lof the chosen cade or standard to the test centre for use inthis open book examination, ‘The procedure must include safety requirements appropriate to the test situation, acceptance levels to specified application standards, NDT personnel approvals, reference documentation, the use of complementary NDT methods, the timing of inspection in relation to manufacture and overhaul, ‘special contractual requirements, action o be taken in case of noncompliance and reporting Instructions (implementation of the procedure) PCNIGEN Appendix A2 oot? Issue 4 cated 1 August 2003,REFERENCE LITERATURE Essential Reading a Bs M36. Method for ultrasonic testing of special forgings by an immersion technique sing flat-bottomed holes as a reference standard. a BS M36: Guide to compilation of instructions and reports forthe in-service Non- Destructive Testing of Aerospace Products. @ BSEN 1330-4 Non-Destructive Testing ~ Glossary of terms used in non-destructive testing Uttrasonic law detection BS EN 12688-3 Non-Destructive Testing - Characterisation and verification of equipment : Part 3. Combined equipment 2 BSEN 583-1 Non-destructive testing ~Ultrasonic examination ~ Part 1: General_ principles 2 BSENS83-3 —Non-destructive testing ~Utrasonic examination ~ Part 3: Transmission technique 2 BSEN 583.5 —_Non-destructive testing -Ultrasonic examination ~ Part 5: Characterisation and sizing of discontinuities 2 BSEN 12223 Calibration block No.1 for ultrasonic examination @ BSEN 12062 —Non-destructive examination of welds General rules for metallic materials 2 BSEN 27063 Calibration block No.2 for ultrasonic examination of welds @ MIL-STD-2184: Process for inspection ultrasonic weld metals 2 MIL-STD-2175: Castings - classification and inspection of Product Technology Classroom Training Handbook. Obtainable from the Certification Services Division, The British Insitute of Non-Destructive Testing, 1 Spencer Parade, Northampton NN1 BAA, Training Course Notes Candidates may have attended an approved course of training, Accredited Training Establishments are required to provide trainees with an up to date set of training course notes, These are considered essential reading Recommended Reading 2 Civil Aviation Airworthiness Inspection Procedures Part 4 leaflet 4.8 Basic Metallurgy for Non-Destructive Testing, Edited by J L Taylor: The British Institute of Non- Destructive Testing, 1 Spencer Parade, Northampton NN1 SAA, ‘American Society for Metals -'Non destructive Inspection and Quality Control : Metals Handbook’ Vol Il. Metals Park, Ohio ‘Materials and Processes for NDT Technology. ASNT. ‘Non-Destructive Testing (Second Edition 1991) by R Halmshaw. Edward Arnold [Non-Destructive Testing Handbook, First edition. Eaited by R McMaster, ASNT Soif Study Handbook (originally published by General Dynamics) [ASNT Classroom Training Handbook (originaly published by General Dynamics) [ASNT Question and Answer book. ASNT Level Il Study Guide ASNT Student Package, ASNT Instructor Package (overheads for training) Some of the above are avaliable only in reference libraries. For information on sources of the above recommended reading, contact the Technical Secretary, The British Institute of Non-Destructive Testing, 1 Spencer Parade, Northampton NNT SAA. ° ooccoocca PCNIGEN Apponcix AZ Tot7 ue 4 dated ¥ August 2003,Certication Services Division 4 Spencer Parade, Northampton NDT NN! SAA, United Kingdom repay mera of Tel vag(yt004250.006, Foe ss(yre08 251889 aR Ema: pen@binatorg (Sa PONIGEN Appond 2:3 EXAMPLE QUESTIONS COVERING THE EXAMINATION OF NDT PERSONNEL FOR ULTRASONIC TESTING OF AEROSPACE MATERIALS COMPONENTS & STRUCTURE ‘This Appendix to PCN General Requirements for Qualifcation and Certification of NOT Personnel provides example questions for PCN examination of personne! engaged in Ultrasonic Non-Destructive ‘Testing of Aerospace Materials, Components and Structures Certifcation issued as 2 result of success in an examination defined herein complies with European standard EN 473, international standard ISO 9712, and may be used by employers of NDT personne! to salisty the quaitication requirements of European Standard EN 4179, ‘Any person requiring information conceming the content of PCN documents should address queries 10 the PCN Scheme Manager at the above address, ASSOCIATED DOCUMENTS: ‘Appendix AO Qualification and certification of NOT personnel for the Aerospace industry mult-sector ‘Appendix 2.1 Qualification and certification of NDT personnel for Ultrasonic Testing of Aerospace Materials Components and Structures, ‘Appendix 42.2 Syllabus for the Examination of Personnel engaged in Ultrasonic Testing of Aerospace Materials Components and Structures, CONTENTS: LeveL 2 offering personnel and quality management systems assessment and oeritication ‘agains criteria set cut in international and EWropean standards through the PCN ‘The British Insitute of Non-Destiuctve Testing is an accredited certification body © Certticavon Scheme,LEVEL 2 General Theory of the Ultrasonic Method 1, The angle at which the shear component of an incident beam is refracted at 80 degrees to the ‘ormal is calle 2) the normal angle of incidence ) the first critical angle ©) the angle of maximum reflection @) the second critical angle 2. As frequency increases in ultrasonic testing the angle of beam divergence of a given diameter crystal 1) decreases ) remains constant ©) increases 4) varies uniformly through each wavelength 3. The fundamental frequency of a piezo-electric crystal used in ultrasonic probes is a function of: 2) its thickness ») the velocity of sound in the crystal material ©) both A and 8 above 4) its diameter 4. Shear waves are generally more sensitive to fine discontinuties for @ given frequency than longitudinal waves because: 4) the wavelength is shorter 'b) shear waves are not as easily dispersed in the material ©) the direction of particle vibration of shear is more sensitive 4) the wavelength of shear waves is longer ‘5. Alinear time base is achieved when the electron beam in the GRT: 4) Is deflected with constant velocity ») is deflected with constant acceleration €) is deflected with the same velocity as the probe movement 1) produces four echoes on the screen Sector Specific Theory of the Application of the Ultrasonic Method in the Testing of Aerospace Products 1. DGS diagrams compare flaw signal amaltudes to: 2) reference blocks ») flat bottomed holes ©) a theoretical maximum ) DAC PONIGEN Appendix A2 2ot? Issue 4 dated 1 August 20032, Given that the velocity of a compression wave in steel is 6000 ms, how long does it take @ wave to travel from one end to the other of a 30mm stee! bolt?” 2) 5 microseconds ) S miliseconds €) 2 microseconds 4) 2 miliseconds. 3. The most appropriate method for sizing lamination in rolled plate would be: a) 0G b) Dac ©) 2048 0) 6cB 4. The vertical axis of the DGS diagram represents: 2) probe diameter ») fat-bottomed hole size ©) gain 8) reflector depth Sector Specific Product Technology Theory Wrought Materials and Components Product Technology Theory 1, Poor forging temperature or too great a reduction in section can give rise to rupturing of the ‘material, this is called a @) fap b) seam ©) burst 4) inclusion 2. The failure of turbine blades at the junction ofthe blade and larger section where it willbe attached {o the rotor, can often be ascribed to cyclical stresses which are concentrated inthis region. The failure mechanism is called 2) stress rupture ») intergranular fretting corrosion ©) fatigue 4) hot tearing Cast Components Product Technology Theory 3. Lage smooth voids or porosity in a casting results from: 8} turbulent flow of metal during pouring ) segregation of alloy constituents ©) gas evolved before and during solidification 4) ot tearing in the thick sections ofthe casting PCNIGEN Appendix A2 Sof? Issue 4 dated 1 August 20034, Discontinuities which originate in the cast ingot can often be reduced by a process which closes and Welds the voids, as well as breaking up inclusions, this process is: a) machining ) welding ©) forging 9) cold extrusion ‘Aerospace Structures Technology Theory 5. Fretting corrosion on a mainplane skin may be identified by: 2) black or greyish brown powder b) awhite deposit on the skin surface ©) severe pitting of the skin surface 4) spitting of the skin edge 6. A structural member described as a longeron is a: a) chordwise member in a wing ») horizontal member in a fuselage ©) spanwise member in a wing 4) circumferential member in a fuselage Safety in the Aerospace Environment 7. Splashes of hydraulic ud in the eyes must be treated by: ) immediately going to the nearest hospital by immediately irrigating the eyes thoroughly with cold clean water ©) gently dabbing the eyes with a clean tissue 4) gently wiping the eyes with a clean damp tissue 8, When working in the vicinity of a moveable fight control surface, itis advisable to: a) mechanically wedge the control surface to prevent movement, ensure that all external and internal power supplies are disconnected. ©) only work near the control surface when no one else is on the aircraft 4) ensure that the aircraft controls are labelled "DO NOT OPERATE CONTROLS" The questions wil be similar to those fr level 2, but generally more compe ‘The examination will test the candidate's understanding of the general theory at level 2 of four out of the radiographic, ultrasonic, eddy current, magnetic particle and liquid penetrant NDT methods to tenable him/her to recognise correct application but not necessarily to specify techniques. PCNIGEN Aopendlx A2 407 Issue 4 dated 1 August 2003,1. Thin sheets of lead fol in intimate contact with radiographic film increase film density because they: 2) fluoresce and emit visible light which helps expose the film ) absorb the scattered radiation ©) prevent backscattered radiation from fogging the fim 4) emit electrons which helps darken the film 2. The fact that gases, when bombarded with radiation, jonise and become electrically conducting ‘make them useful in: 8) X-ray transformers ) Xray tubes o) masks 4) monitoring equipment 3. The most effective method of demagnetisation is. a) AC aperture coil ) reversing and decreasing OC €) stroking with AC yokes 4) hammering along the length of the part 4, For fine, surface breaking cracks the best magnetic particle inspection medium is: a) dry powder, black b) dry powder, fuorescent ©) magnetic ink, black 4) magnetic ink, fluorescent 5. Water washable penetrants require longer dwell times than solvent removable versions because of the presence of 2) emulsifier ») stabiliser ©) penetrant remover 9) contaminants 6. The property of a iquid which affects the speed of flow is: 2) surface tension b) viscosity ©) contact angle 4) a combination ofall the above 7. In eddy current test systems where encircling cols are used, coupling efficiency is referred to as: 2) Hit of by edge factor ©) fil factor 4) phase dliferentiation PONIGEN Appendix AZ Sof? Issue 4 dated 1 August 2003,‘8. When the voltage applied to a circuit and the current through the circuit both reach their maximums al the same time the voltage and current are 2) additive ) in phase ©) regenerate 4) out of phase ©. The angle at which the sheer component of an incident beam is refracted at 80 degrees tothe ‘) the normal angle of incidence ) the fist critical angle ©) the angle of maximum reflection 4) the second critical angle 10. As frequency increases in ultrasonic testing the angle of beam divergence of a given diameter crystal 4) decreases : by remains constant ©) increases ) varies uniformly through each wavelength Knowledge of the Requirements for PCN Certification 1. The minimum period of experience required to be eligible for the level 2 Ultrasonic examination is: 2) 3 months, b) 12 months: ©) 9 months. 6) 8 months. 2. PON candidates shall have near distance acuity, corrected or uncorrected, in at least one eye, such that the candidate is capable of reading 2) Jaeger number 1 letters at not less than 30cm ) Jaeger number 1 letters at not more than 30 om ©) Jaeger number 1 letters at 300 cm 6) Jaeger number 1 letters at 30 cm Sector Specific Theory of the Apy Products: tion of the Ultrasonic Method in the Testing of Aerospace No examples of multiple choice answer questions (which will be similar to those for level 2, but ‘generally more complex) are currently provided. PCNIGEN Appendix A2 oot? Issue 4 cated 1 August 2003,