PRC-6509 Rev.

Process Specification for Eddy Current

Inspection

Engineering Directorate

Structural Engineering Division

January 2019

National Aeronautics and

Space Administration

Lyndon B. Johnson Space Center

Houston, Texas

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 PRC-6509 Rev. E

Process Specification for Eddy Current Inspection

Reviewed and
Prepared by: Signature on File 01/07/2020
Ajay Koshti Date
Materials and Processes Branch/ES4

Reviewed and
Prepared by Signature on File 01/07/2020
David Stanley Date
Materials and Processes Branch/ES4

Reviewed and
Prepared by Signature on File 01/07/2020
Norman Ruffino Date
Materials and Processes Branch/ES4

Reviewed and
Prepared by Signature on File 01/07/2020
Miles Skow Date
Materials and Processes Branch/ES4

Approved by: Signature on File 01/21/2020

Brian Mayeaux Date
Materials and Processes Branch/ES4

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 PRC-6509 Rev. E

REVISIONS
VERSION CHANGES DATE
-- Original version 12/01/2000
A Reviewed document per QMS requirements. 04/22/2004
Updated division name, organization codes, and
document numbers.

B Added new NOE calibration notch classes and 05/01/2008

NOE standards. Added applicability to inspection
of bolts. Defined standard NOE and special NOE
in terms of
calibration notch size and crack detectability
C Added "array probes or wide area coverage probes"
in para 2.1. Added source-detector probes in para. 9/30/2010
5.5.1.2. Added explanation on crack detectability size
in paragraph 5.5.4.5.

D Added SNT-TC-1A to paragraph 4.0. Revised 6/29/2011

paragraph 8.0 for uniformity across all NOE
PRCs.
E Added NASA-STD-50098 requirements and edited 12/16/2019
for clarity.

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 PRC-6509 Rev. E

1.0 SCOPE

This process specification establishes the minimum requirements for eddy current
inspection of flat surfaces, fastener holes, threaded fasteners and seamless and welded
tubular products made from nonmagnetic alloys such as aluminum and stainless steel.

2.0 APPLICABILITY

This specification is primarily applicable to in-process, final, and in-service eddy current
inspections to detect surface and near surface cracks and crack-like flaws that are more
or less normal to the inspection surface. However, usage is not limited to those
applications.

2.1 FLAT SURFACES AND UNIFORM SECTION CORNERS

This specification is applicable to the inspection of relatively flat surfaces and uniform
cross section edges and corners with a surface finish of 125 µin Ra or better. This process
shall be used for directed inspections of critical or damaged areas. It shall not be used for
global inspection of areas greater than 2 sq. ft. unless automated scanning equipment,
array probes or wide area coverage probes are used.

2.2 FASTENER HOLES

This specification is applicable to the inspection of open fastener holes with an interior
surface finish of 125 µin. Ra or better using a rotating probe hole scanner or a manual
bolt hole probe.

2.3 THREADED FASTENERS

This specification is applicable to the inspection of fastener thread roots, shank surfaces,
shank neck down regions, and the fillet radius under the bolt head with a surface finish of
125 µin. Ra or better and fillet radius of 1/32 in. or greater.

2.4 TUBULAR PRODUCTS

This specification is applicable to the inspection of both seamless and welded tubular
products using either an encircling or probe coil technique. The use of ID probe
techniques is not covered. This specification covers the inspection of tubular products
ranging in diameter from 0.125 to 5 in. with wall thicknesses ranging from 0.005 to 0.250
in.

3.0 USAGE

This specification shall be invoked by an inspection callout on the engineering drawing

or by a reference in a Process Specification, Task Performance Sheet, Discrepancy
Report/Material Review Record, or other appropriate work authorizing document. The
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engineering drawing or referencing document shall identify the specific part features or
areas that require inspection. A typical eddy current inspection callout would be:

EDDY CURRENT INSPECT ALL HOLES PER NASA/JSC PRC-6509 TO

STANDARD LEVEL NOE.

When fracture control requirements necessitate Special Nondestructive Evaluation

(NOE) of a fracture critical component, the requirement for Special NDE shall appear in
the inspection callout and the specific inspection procedure and inspector shall be
qualified in accordance with Section 6.0. A typical Special NDE eddy current inspection
callout would be:

EDDY CURRENT INSPECT AREA SHOWN PER NASA/JSC PRC-6509 TO

SPECIAL LEVEL NDE. SPECIAL NDE CERTIFICATION REQUIRED.

3.1 INSPECTION SEQUENCE

The stage in the manufacturing process where inspection is performed should be

specified on the engineering drawing or in the referencing document.

3.2 ACCEPTANCE CRITERIA

Any indication greater than 50 percent of the peak response from the reference notch
shall be cause for rejection. For fracture critical parts, any indication greater than 50
percent of the reference notch response shall be reported to, and receive disposition by,
the proper engineering authority.

4.0 REFERENCES

The following specifications, standards, and handbooks form a part of this document to
the extent specified herein. All documents listed are assumed to be the current revision
unless a specific revision is listed. In case of conflict between this specification and the
technical requirements cited in other referenced documents, the requirements of this
document take precedence.

ASTM E 1742 Standard Practice for Radiographic Examination.

NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture

Critical Metallic Components.

NAS 410 NAS Certification & Qualification of Nondestructive Test

Personnel.

SNT-TC-1A Personnel Qualification and Certification in

Nondestructive Testing.

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NASA-STD-5019 Fracture Control Requirements for Spaceflight

Hardware.

PRC-5010 Process Specification for Pickling, Etching, and

Descaling of Metals.

SAE ARP4402 Eddy Current Inspection of Open Fastener Holes in

Aluminum Aircraft Structure.

SAE AS4787 Eddy Current Inspection of Circular Holes in Nonferrous

Metallic Aircraft Engine Hardware.

SNT-TC-1A Personnel Qualification and Certification in

Nondestructive Testing.

The following references were used to develop this process specification:

SOP-007.1 Preparation and Revision of Process Specifications

(PRC's).

JSC 8500 Preparation and Revision of Process Specifications.

SAE ARP K99-AA Eddy Current Surface Crack Detection in Aerospace

Structures (Draft document prepared by SAE AMS
Committee K, Nondestructive Methods and Processes).

5.0 PROCESS REQUIREMENTS

5.1 GENERAL

Eddy current inspection of flat surfaces and threaded fasteners shall be performed in
accordance with this specification. Fastener holes in aluminum parts shall be inspected
in accordance with SAE ARP4402 and in other alloys in accordance with SAE AS4787
except as modified by this specification. Inspection of tubular products shall be
performed in accordance with ASTM E 426 except as modified by this specification.

5.2 WRITTEN PROCEDURES

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A written inspection procedure shall be used for inspection of each part. The procedure
shall meet the requirements of this specification and shall ensure the consistency and
reproducibility of the inspection at the required sensitivity level. General procedures
covering a variety of different parts may be used provided they meet the requirements of
this specification and clearly apply to the parts to be inspected. When general procedures
are used, a written part specific technique shall be prepared. Each procedure and
technique shall be approved by a Level Ill inspector or by a cognizant NDE engineer.

At a minimum, the part specific procedure or the general procedure and part specific
technique shall include the following:

• The applicable part name and number

• A description of the part, area of the part, or hole configuration to be inspected
• The alloy type and conductivity
• The potential defect location and orientation, if known
• The applicable eddy current instrument, probes, and fixturing equipment including
the manufacturer and model numbers
• The applicable calibration standard and its conductivity
• The test frequency
• Part cleaning and preparation instructions
• Equipment setup, calibration, and operation procedures
• Scan plan indicating areas covered by the inspection and any limitations
• Procedure for evaluation of questionable indications

A copy of the inspection procedure shall be provided to the customer upon request.

5.3 SCAN PLAN

Unless otherwise specified in the engineering drawing or in the referencing document,

scan plans shall be designed to detect discontinuities in all credible orientations. The scan
plan should document the expected crack directions, probe orientations, scan directions,
scan index, effective probe width, scan overlap, probe holders and scanning aids.

5.3.1 ASSUMED CRACK ORIENTATIONS

When the direction of principal stress is known, cracks are assumed to be oriented normal
to the stress direction. The scanning direction shall be within ±45 degrees of the principal
stress direction with a scan index width of no more than one-half of the effective probe or
field diameter. Moreover, the effective probe or field diameter should not exceed the
target crack length by more than 50%.
For external corners, cracks are assumed to be oriented normal to the corner. For internal
corners, cracks are assumed to be oriented both parallel and normal to the corner.

For threaded fasteners, cracks at the thread root are assumed to be oriented in the
helical/circumferential direction. For the shank, cracks are assumed to be oriented in both

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the axial and circumferential directions. Cracks in neck down areas and in the radius
between the fastener head and the shank are assumed to be oriented in the
circumferential direction. Thread terminations on the shank side cannot be inspected
unless a relief zone is provided.

For fastener holes, cracks are assumed to be oriented axially.

5.4 REPORTS

An inspection report shall be prepared for each part or group of parts. The report shall
indicate compliance with this specification, reference the appropriate written procedure
and include the names of personnel performing the inspection. The report shall identify
each part by part number and serial number and indicate whether each part was accepted
or rejected. The report shall include a description of the inspection coverage and any
limitations. The locations and estimated sizes of all reportable flaws shall be noted in the
inspection report. Inspection reports shall be retained as a permanent quality record and
a copy provided to the responsible design authority.

5.5 EQUIPMENT

Instrument/probe combinations shall be capable of meeting the calibration requirements

of Section 5.7. During inspection operations equipment shall be located at least 10 ft. from
any items that generate a large magnetic field, such as motors, generators, and
transformers.

5.5.1 INSTRUMENTS

Instruments shall be equipped with impedance plane or time base signal display.
Instruments shall be capable of operating between 100 kHz and 6.0 MHz. However,
instruments may be operated at other frequencies if the requirements of Section 5.7 are
met. Instruments shall be equipped with an audible and/or visual alarm system. For other
than battery-powered instruments, a voltage regulator shall be used if instrument internal
voltage regulators are not adequate to prevent a signal variation of 20% or more.

5.5.2 PROBES

The recommended frequency range for aluminum alloys is 100 - 500 kHz and 800 kHz -
3.5 MHz for lnconel, CRES, and titanium alloys.

Probes should be marked with their operating frequency range. The recommended
maximum coil diameter is 0.125 inch for single coil and array probes used for detection
of surface flaws. The impedance of probes and adapters shall match the instrument being
used. Probes may have an absolute, differential, or source-detector coil arrangement and
may be shielded or unshielded. Differential and source-detector probes shall be oriented
appropriately with respect to the expected crack direction during scanning. Probes shall
not give interfering responses from handling pressure or manipulation and meet the noise

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ratio requirements in Section 5.7.4.

Effective scanning requires a uniform material form factor and lift-off throughout the scan
area. For manual scans probe guides such as non-metallic rulers or stencils should be
used to ensure uniformity of the material form factor and scan indexing. Moreover, probe
collars or edge/corner probes should be used when possible to reduce lift-off effects.
When inspecting for cracks in concave surfaces, the probe tip shall be convex and shall
nest in the radius with less than
0.005 in. lift-off.

Non-conductive tape may be applied over the probe tip to protect the probe coil and part
from wear. If tape is used, calibration shall be performed after initial application and
anytime it is replaced. Use of tape shall not violate the noise ratio requirements.

5.5.3 SCANNERS

Automated scanning systems may be used to obtain controlled lift-off and indexing
between scans. If an automated scanner is used, the calibration procedure shall include
scanning of the reference standard to verify that the appropriate sensitivity level and noise
ratio requirements are achieved. Hand scanning may employ encoder or time scan for
data acquisition. Any tape applied to the probe should be periodically checked for wear
and replaced if necessary.

5.5.4 RECORDING DEVICES

Data recording devices, when used, shall be compatible with the instrument and capable
of generating a permanent record or copy of the signal response.

5.5.5 REFERENCE STANDARDS

5.5.5.1 CONDUCTIVITY

For parts with a conductivity less than 10% IACS, the reference standard conductivity
shall be within ±2% IACS of the part conductivity with a minimum reference standard
conductivity of 0.8% IACS. For parts with a conductivity of 10% IACS or greater, the
reference standard conductivity shall be within ±15% of the part conductivity. When the
part has a coating, a shim or coating with the same conductivity (±5% IACS) and thickness
(+0.003''/-0.000") as the part coating shall be placed on the reference standard during
instrument calibration.

5.5.5.2 EDM NOTCHES

Reference standards shall contain one or more of the EDM notches specified in Table 1.
Other EDM notches may be used provided the peak vertical notch response is less than
or equal to the peak vertical response from the largest acceptable fatigue crack.

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Table 1: EDM Notch Dimensions (Inches)

Primary Notches Alternative Notches
Rectangular Long Notches (Length Rectangular Through Notches at the Edge
Semi-Circular Surface Notches Radial Corner Notches >0.75) of 0.1 Thick Sheet or Plate
Class Length Depth Width Radius Width Designation Depth Width Designati Depth Width
on
A0 0.015 ±0.002 0.007 ±0.001 ≤ 0.004 0.010 ±0.001 ≤ 0.004 . . .
A1 0.020 ±0.002 0.010 ±0.001 ≤ 0.004 0.014 ±0.001 ≤ 0.004 L1 0.001 - 0.002 ≤ Depth T1 0.001 - 0.002 ≤ Depth
A2 0.025 ±0.002 0.012 ±0.001 ≤ 0.004 0.017 ±0.001 ≤ 0.004 L2 0.002 - 0.003 ≤ Depth T2 0.003 - 0.004 ≤ Depth
A3 0.030 ±0.002 0.015 ±0.002 ≤ 0.004 0.021 ±0.002 ≤ 0.004 L3 0.003 - 0.004 ≤ Depth T3 0.004 - 0.005 ≤ Depth
A4 0.040 ±0.002 0.020 ±0.002 ≤ 0.004 0.028 ±0.002 ≤ 0.004 L4 0.005 - 0.006 ≤ 0.004 T4 0.008 - 0.007 ≤ 0.004
A5 0.050 ±0.002 0.025 ±0.002 ≤ 0.004 0.035 ±0.002 ≤ 0.004 L5 0.008 - 0.010 ≤ 0.004 T5 0.009 - 0.011 ≤ 0.004
A6 0.060 ±0.002 0.030 ±0.002 ≤ 0.004 0.042 ±0.002 ≤ 0.004 LS 0.011 -0.013 ≤ 0.004 T6 0.013 - 0.015 ≤ 0.004
A7 0.070 ±0.002 0.035 ±0.002 ≤ 0.004 0.049 ±0.002 ≤ 0.004 L7 0.015 - 0.017 ≤ 0.004 T7 0.018 -• 0.020 ≤ 0.004

Semi-circular surface notches shall be used to establish the required sensitivity level for
inspection of relatively flat surfaces, fillet radii, thread roots, and fastener shanks. Radial
corner notches shall be used for inspections of external comers. Rectangular through
notches shall be used for inspections of edges 0.1 inch thick or less. Rectangular long
notches may be selected for use with any surface geometry based on a comparison of
the signal response from the long notch to the eddy current response from the applicable
semi-circular surface, radial corner, or rectangular through notch.

5.5.5.3 CONFIGURATION

Schematics for typical reference standards are given Figures 1 through 5. The notch
dimensions are in accordance with the applicable notch class in Table 1. Air Force
7947479 series general purpose standards may be used for fastener hole inspections. The
as-built dimensions, in particular EDM notch dimensions, shall be measured and
documented. Reference standards shall be certified when required by the responsible
engineering organization.

Table 2 contains a listing of conforming reference standards available through Olympus NDT.

Figure 1: Surface Notch Reference Standard

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Figure 2: Corner Notch Reference Standard

Figure 3: Long Notch Reference Standard.

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Figure 4: Through Notch Reference Standard

Figure 5: Threaded Fastner Reference Standard (Notch 4 and 4 at Thread Root)

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Table 2: Applicable Eddy Current Crack Detection Standards

Part# Material Description

7947479-6AL4V-10 6AL-4V Titanium Air Force General Purpose Eddy Current

Standard
7947479-304-10 304 Stainless Steel Air Force General Purpose Eddy Current
Standard
7947479-7075T6-10 7075-T6 Aluminum Air Force General Purpose Eddy Current
Standard

NEC-6365-2024T8 2024-T3 Alum, 30.08% IACS Surface Notch Standard

NEC-6365-2024T8 2024-T8 Alum, 40.4% IACS Surface Notch Standard
NEC-6366-2024T8 2024-T8 Alum, 40.37% IACS Corner Notch Standard
NEC-6366-2024T3 2024-T3 Alum, 29.65% IACS Corner Notch Standard
NEC-6367-2024T8 2024-T8 Alum, 40.64% IACS Long Notch standard
NEC-6367-2024T3 2024-T3 Alum, 29.55% IACS Long Notch standard
NEC-6368-2024T3 2024-T3 Alum, 29.92% IACS Thru Notch standard
NEC-6368-2024 T8 2024-T8 Alum, 39.98% IACS Thru Notch standard

NEC-6365-718 lnconel 718, 1.43 %IACS Surface Notch standard

NEC-6365-304 CRES 304, 2.52 %IACS Surface Notch standard
NEC-6365-6Al-4V 6Al-4V, 1.05 %!ACS Surface Notch standard

NEC-6367-718 lnconel 718, 1.44 %IACS Long Notch standard

NEC-6367-304 CRES 304, 2.45 %IACS Long Notch standard
NEC-6367-6Al-4V 6Al-4V, 1.04 %IACS Long Notch standard

NEC-6366-718 lnconel 718, 1.43 %!ACS Corner Notch standard

NEC-6366-304 CRES 304, 2.52 %!ACS Corner Notch standard
NEC-6366-6Al-4V 6Al-4V, 1.04 %IACS Corner Notch standard

NEC-6368-718 lnconel 718, 1.26 %IACS Through Notch standard

NEC-6368-304 CRES 304, 1.83 %IACS Through Notch standard
NEC-6368-6Al-4V 6Al-4V, 0.98 %IACS Through Notch standard

5.6 PART PREPARATION

Dirt, grease, and/or loose paint shall be cleaned from the inspection surface. If
necessary, determine the thickness of any coating with a coating thickness gage. A similar
type and thickness shim or coating shall be placed over the reference standard for
calibration (refer to Section 5.5.5.1).

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5.7 CALIBRATION

5.7.1 GENERAL

Inspection equipment shall be calibrated against the appropriate reference standard and
EDM notch as specified in Sections 5.5.5 and 5.7.3. Evaluation of flaw indications shall
be accomplished using a signal versus EDM notch size curve obtained on the reference
standard notches.

5.7.2 CALIBRATION INTERVAL

Calibration shall be performed at the beginning and end of each inspection operation and
at least every four hours in between. Calibration shall also be performed if equipment is
changed or replaced. If the response from the reference standard notch has changed by
more than 5% of full scale from the original calibration, perform one of the following:

1. If the notch response is greater than that obtained during the original calibration,
recalibrate and re-inspect any part which was rejected since the last calibration.

2. If the notch response is less than that obtained during the original calibration,
recalibrate and re-inspect all parts inspected since the last calibration.

5.7.3 SENSITIVITY LEVELS AND NOTCH CLASSES

The required sensitivity level is achieved by use of the appropriate EDM notch for
calibration and by meeting the other requirements of this specification. The primary EDM
notches in Table 1 are classified from AO to A7 in order of increasing size. Therefore,
calibration using an A3 notch results in a higher sensitivity level than using an A4 notch.
The alternative long notches (L1 to L7) and through notches (T1 to T7) are similarly
designated in order of increasing size.

The calibration notch class for a given sensitivity level shall be selected in accordance
with Table 3. When Standard or Special NOE sensitivity levels are not applicable or when
the Special NOE crack size is other than that indicated in Table 3, the calibration notch
class shall be selected based on a comparison of eddy current responses from fatigue
cracks of the relevant size and geometry and EDM notches of the relevant geometry. An
EDM notch producing a response less than or equal to the response from the relevant
fatigue crack shall be selected for calibration.

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Table 3: Sensitivity and Class of Calibration Notch

Sensitivity Notch Comment
Level Class
Standard NDE1 A33 Default notch class.
Standard NDE1 A4 Acceptable if A3 notch does not meet noise ratio
requirements.
Standard NDE1 AS Acceptable if A4 notch does not meet noise ratio
requirements.
Special NDE2 A2 Default notch class.
Special NDE2 A3 Acceptable if A2 notch does not meet noise ratio
requirements.
Special NDE2 A4 Acceptable if A3 notch does not meet noise ratio
requirements.
Note 1. Standard NOE surface crack size of 0.100" long x 0.050" deep (or greater) and corner
crack size of 0.075" long x 0.075" deep (or greater).

Note 2. Typical Special NOE surface crack size of 0.050" long x 0.025" deep (or greater) and
corner crack size of 0.035" long x 0.035" deep (or greater). Special NOE qualification in accordance
with Section 6.0 is required.

Note 3. The ratio of crack length to EDM notch length providing the same eddy current amplitude
is assumed to be from 1.5 to 2 for Class A3 with an optimum eddy current set-up.

For Standard NOE inspections of fracture critical components, calibration notches shall
be no larger than the following:

(1) Rectangular Surface Notch: 0.050 ±0.002 in. long by 0.025 ±0.002 in. deep and ≤
0.005 in. wide.
(2) Triangular Corner Notch: 0.035 ±0.002 in. long by 0.035 ±0.002 in. deep by ≤
0.005 in. wide.
(3) Rectangular Through Edge Notch (part thickness s 0.1 in.): ≤ 0.1 in. long by 0.010
±0.001 in. deep by ≤ 0.005 in wide.

5.7.4 NOISE RATIO

Inspection sensitivities for scanning and evaluation are different. However, the reject level
setting is the same during part scanning and indication evaluation. The reject level is set
to 50% of the maximized vertical response from the calibration notch. The ratio of the
reject level to the observed noise, called the threshold to noise ratio (TNR), shall be
visually assessed during calibration, scanning and evaluation. During calibration on the
reference notch the TNR ratio shall be 3:1 or greater. During part scanning, the TNR ratio
shall be 2:1 or greater. Noise is measured as maximum of peak responses from a non-
indication area or background outside indication area {~99 percentile noise).

For Standard NOE inspections of fracture critical components, noise levels on the

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component shall be less than 25 percent of the reference notch response and the
influence of coatings and lift-off variations on the reliability of the inspection shall be
evaluated for application-specific suitability and documented in the NOE Summary
Report.

5.7.5 SCANNING

Reference standards shall be scanned at the same speed as the component with the
probe scanning over the reference notch in the same relative direction as the expected
crack in the component. If the expected crack direction is not known, scans shall be
performed in two orthogonal directions or the calibration notch shall be scanned in the
most unfavorable direction with respect to peak response when establishing the reject
level. Whenever possible, 4 to 6 dB vertical gain shall added during component scans
without changing the reject level. However, indications shall be optimized and evaluated
at the calibration gain. If an alarm is used, the alarm level should be less than or equal to
the reject level.

5.7.5.1 SCAN INDEX

The scan index for both manual and automated scans shall not exceed one-half of the
effective probe coil or field diameter. For shielded probes the effective probe coil diameter
shall be equal to probe diameter. For unshielded single coil probes, the effective probe
coil width shall be based on scans of the calibration notch. The distance between closely
spaced parallel scans of the calibration notch that produce indications that are 50 percent
of the peak notch response shall be considered the effective probe coil or field diameter.
For array probes, the effective probe coil or field width is the distance between the centers
of the first and last coils in the array. The minimum overlap between adjacent scans shall
be equal to the spacing between two adjacent coils.

5.8 INTERPRETATION OF INDICATIONS

The presence of a potential crack is indicated by a rapid signal response similar in

appearance to the reference notch response. Once an indication is detected it shall be
evaluated at the calibration gain. The indication should be carefully rescanned to
maximize the indication amplitude by finding the most favorable scan direction and
location. Compare the maximized response to the maximized calibration notch response.
A response amplitude greater than 50% of the calibration notch response indicates the
presence of a crack. Indications showing less than 50% of the calibration notch response
may indicate a defect condition. The following steps should be taken to evaluate the
significance of such indications:

1. Non-conductive coatings may reduce the amplitude of the crack signal. Assess
coating thickness and compensate for the coating thickness.

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2. Smeared metal on the surface of the part may reduce the amplitude of the crack
signal. Etch the part per PRC-5010, section 6.3.2 "Etching for Penetrant
Inspection", re-calibrate, and re-inspect.

3. If the defect condition is at an edge, use an edge guide with the slotted reference
standard and re-calibrate. Using the edge guide, re-inspect the part.

6.0 SPECIAL NDE QUALIFICATION

Use of Special NDE in accordance with NASA-STD-5009 requires formal demonstration

of the capability to detect Cracks at least as small as the critical initial crack size for the
specific component to a 90/95 probability of detection level. Each procedure, procedure
application, and operator must demonstrate the required capability. Requests for Special
NDE qualification shall be directed to the JSC Materials and Processes Branch (ES4).

7.0 DEVIATIONS AND WAIVERS

Any deviations or waivers regarding the use of this process specification shall be
requested in writing. This request shall be directed to the JSC Materials and Processes
Branch (ES4) with the appropriate justification and rationale. A written response will be
provided upon such a request.

8.0 TRAINING AND CERTIFICATION OF PERSONNEL

Personnel performing acceptance inspections of Class I, II, IIIW and GSE hardware shall
be qualified and certified, at a minimum, to Level 2 in accordance with NAS 410.
Personnel performing acceptance inspections requiring Special NDE shall also be
qualified and certified for Special NDE in accordance with NASA-STD-5009 (Section 6.0).

Personnel performing acceptance inspections of Class Ill, STE/D, mockup, and facility
hardware shall be qualified and certified in accordance with either NAS
410 or SNT-TC-1A. Personnel making accept/reject decisions shall, at a minimum, be
certified to Level 2. Level 3 personnel making accept/reject decisions shall have
successfully completed a hands-on practical examination equivalent to the examination
required for Level 2. Level 1 personnel may perform acceptance inspections under the
direct supervision of a Level 2 but shall not make accept/reject decisions.

Formal qualification and certification is not required for personnel performing engineering
evaluation inspections.

9.0 DEFINITIONS

90/95 The point where the 95% lower confidence bound on

the Probability of Detection (POD) vs. Crack size
curve crosses 90% POD.

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Probability of Detection The point where the 95% lower confidence bound on the
(POD) vs. Crack size curve crosses 90% POD.

Compound Comer A comer formed by intersection of three or more surfaces.

Internal comer is concave in shape and external comer is
convex in shape.

EDM Electrical Discharge Machining

Final Inspection The final inspection performed for the acceptance of the
component.

Fracture Critical Classification which assumes that fracture or failure of the

Component component resulting from the occurrence of a crack will
result in a catastrophic hazard. Fracture critical components
will be identified as such on the engineering drawing.

Indication In- Evidence of a discontinuity that requires interpretation to

determine its significance.

Process In- Inspections which occur during manufacturing before a

component is in final form.

Service Inspections performed on components that are in use or

storage.

NAS National Aerospace Standard

Noise Noise is measured as maximum of peak-to-peak amplitude

sampled from non-indication area or background outside
indication area. Noise sample shall have at least 40
measurements.

SAE International
SAE

Special NDE A fracture control term denoting nondestructive inspection

personnel, procedures, and equipment with a demonstrated
capability to reliably (90/95) detect flaws smaller than those
normally detected by typical procedures.

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