Aviation NDT: Improving Flight Safety With Cutting-Edge Inspection Solutions

The top priority of aerospace companies is to keep their pilots, passengers, and crews safe in the air and on the ground. To prevent dangerous and costly equipment failure, the aviation industry routinely performs nondestructive testing (NDT). Aviation NDT is frequently required by law, typically according to standards set by independent associations or organizations, depending on the country. 

Many NDT techniques have been used in the aerospace field, dating to the early days of flight. Two of the most common methods relied on in modern practice are ultrasonic testing (UT) and eddy current testing (ECT). Ultrasonic testing scans aircraft components using high-pitched acoustic sound waves, while eddy current scans use electromagnetic energy to image thin, conductive materials.

Based on our decades of experience providing ultrasonic and eddy current NDT equipment to aerospace firms, Zetec has written a wide array of articles relevant to the industry. To provide a guide to current aviation NDT practices, we’ve collected several timely, useful articles on a range of related topics. 

Common Aviation NDT Applications & Techniques

Airplanes and spacecraft are complex, interconnected systems, built from a wide variety of materials and subjected to significant stress during takeoff, flight, and landing. Most systems require regular inspections for safety, but not all systems can be inspected using the same method. To help you find which inspection method is most appropriate for your specific inspection application, we’ve compiled a list of common aerospace NDT applications and solutions. 

Read more about aerospace NDT applications and solutions. 

Commercial aircraft require the bulk of aerospace NDT, due to their size and number. While UT and ECT are commonly used in commercial aircraft, other techniques have been used as well. Additionally, different types of ultrasonic and eddy current testing—such as phased array ultrasonic testing (PAUT)—can improve inspection efficiency and accuracy. 

Read more about NDT techniques for commercial aircraft. 

Aircraft wheel inspection is a common NDT inspection. The high number of wheel inspections that must be performed demands an efficient testing solution. While liquid dye penetrant testing has been used to inspect aircraft wheels in the past, this method is slow, cumbersome, and difficult to digitize. To improve inspection times and accuracy, aviation companies have upgraded to eddy current testing for wheel inspections. 

Read more about aircraft wheel NDT tools. 

Aircraft propellers are integral to flight safety, but stress and exposure can cause defects like cracks. Some defects are undetectable by the human eye, requiring advanced NDT inspections. Propellers are typically fabricated from alloys or composites and, depending on their material, they can be inspected using different techniques. Eddy current testing is preferred for conductive alloys, while ultrasonic testing is commonly used to inspect composites. 

Read more about propeller inspection NDT.  

Selecting NDT Equipment & Supplies

NDT aviation equipment has to be fast, accurate, and durable. Portability is also a lauded aspect of NDT equipment for aircraft, as it helps technicians reach areas that are difficult to scan. It helps reduce user fatigue as well, which can lead to more productive testing. The best aviation NDT suppliers have significant experience in the field, top-rated equipment, and excellent customer service.

Read more about finding the best aviation NDT supplies. 

Advances in NDT technology have improved inspection processes in the aviation industry. Automated scanning solutions increase inspection capacity without sacrificing accuracy. Large surfaces with complex geometry, which are common in aircraft, can be inspected more effectively with automated scanners.

Read more about automated NDT equipment for aerospace. 

Managing aircraft maintenance requires the right information, at the right time. NDT equipment with top-shelf modern software can simplify aircraft maintenance by keeping detailed records of scans and defects. These records inform maintenance scheduling and inventory management. 

Read more about managing aircraft maintenance with NDT inspection technology. 

Inspecting Carbon Fiber & Composites 

Carbon fiber has become increasingly popular in aerospace design and manufacturing and can be found in many fleets. While this light, rigid material is wonderful for aircraft construction, it is also subject to the damage and defects which plague more traditional materials, like aluminum and steel alloys. Effective nondestructive testing can detect these issues before they become flight hazards. 

Read more about NDT for carbon fiber. 

Carbon fiber is not used by itself in aircraft construction, but rather in a composite form. It has different properties than traditional alloys and requires different inspection techniques. Understanding these differences helps managers choose the right NDT equipment and helps technicians make smart choices during inspection. 

Read more about NDT strategies for aerospace composites. 

Composite materials pose unique challenges for NDT inspectors. The best NDT equipment for composites can detect cracks, fractures, voids, delamination, and honeycombing in multilayer composite structures. The optimal equipment will be able to handle these complex inspections efficiently and accurately while keeping detailed inspection records. 

Read more about the best NDT equipment for composite materials. 

While standard PAUT is often successfully deployed to inspect aerospace composites, areas with variable thicknesses and complex geometries can create inspection speed difficulties, particularly when using automated scanners. Ultrasonic equipment capable of using the time-reversal algorithm obviates this issue by compensating for the probe alignment issues which can arise during these automated inspections, improving both the pace and accuracy of testing. 

Read more about using time-reversal phased array ultrasonic for automated composite inspections. 

Meeting Standards & Ensuring Compliance 

The U.S., the E.U., and most countries around the world require nondestructive testing of aircraft. While many of these governmental regulations are based on the work of international bodies of experts, such as ISO, not all of them are, and some interpret standards differently. To avoid regulatory penalties, aerospace companies must understand and obey pertaining NDT standards and regulations in all countries where they operate. 

Read more about NDT standards for aviation.

Maintaining Readiness in Military Aviation 

To ensure mission readiness, military air fleets require nondestructive testing regimens. Military standards can be more stringent than civilian NDT regulations, and military air fleet maintenance managers must understand them thoroughly in order to maintain compliance. When sourcing NDT equipment for military air fleets, speed, accuracy, durability, and recordkeeping abilities are prized. 

Read more about nondestructive testing in the air force. 

NDT is an essential capability in the aviation industry. Not only is it required by law, but it’s also the difference between hoping a flight will be safe, and knowing that flight will be safe. The volume of inspections that must be performed in the industry requires equipment that can perform speedy inspections without missing the smallest crack. The right NDT equipment supplier will provide not only the best equipment but expert advice and helpful customer service as well. 

Zetec has been a proud provider of NDT equipment for aviation for several decades. To learn more about our ultrasonic and eddy current testing equipment, contact us today.