1、 INCH POUND MIL-HDBK-6870B 14 February 2012 SUPERSEDING MIL-HDBK-6870A 28 August 2001 DEPARTMENT OF DEFENSE HANDBOOK NONDESTRUCTIVE INSPECTION PROGRAM REQUIREMENTS FOR AIRCRAFT AND MISSILE MATERIALS AND PARTS This handbook is for guidance only. Do not cite this document as a requirement. AMSC N/A AR
2、EA NDTI DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B ii FOREWORD 1. This handbook is approved for use by all Departments and Agencies of the Departmen
3、t of Defense (DoD). 2. This handbook provides the guidance for defining the requirements for establishing a nondestructive inspection (NDI) program for evaluation of structural components in development, production or sustainment of aircraft and missiles systems. This document is directly applicable
4、 when referenced in the item specification contract or order. 3. Comments, suggestions, or questions regarding this document should be addressed to ASC/ENRS, 2145 Monahan Way, Wright-Patterson AFB, OH 45433-7017 or e-mailed to Engineering.Standardswpafb.af.mil. Since contact information can change,
5、you may want to verify the currency of this address information using the ASSIST Online database at https:/assist.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B iii CONTENTS Paragraph Page 1. SCOPE 1 1.1 Scope. 1 1.2 Applicab
6、ility. 1 2. APPLICABLE DOCUMENTS 1 2.1 General 1 2.2 Government documents. 1 2.2.1 Specifications, standards, and handbooks. 1 2.2.2 Other Government documents. 2 2.3 Non-Government publications. 2 3. DEFINITIONS 4 3.1 Inspector certification. 4 3.2 Classification. 4 3.3 Contracting agency. 4 3.4 Co
7、ntractor. 4 3.5 Final inspection. 4 3.6 Fracture-critical part. 4 3.7 Fracture-critical traceable part. 4 3.8 Maintenance-critical part. 4 3.9 Mission-critical part. 5 3.10 Material Review Board (MRB). 5 3.11 Nondestructive inspection (NDI). 5 3.12 Nondestructive inspection (NDI) procedure. 5 3.12.1
8、 General NDI procedure. 5 3.12.2 Part specific NDI procedures. 5 3.13 NDI facility. 5 3.14 NDI Program Plan. 5 3.15 NDI process specification. 5 3.16 NDI Requirements Review Board (NDIRRB). 6 3.17 Probability of detection (POD). 6 3.18 Qualification. 6 3.19 Safety-of-flight structure. 6 3.20 Subcont
9、ractors. 6 3.21 Supplier. 6 4. GENERAL REQUIREMENTS 6 4.1 Preparation of the NDI Program Plan. 7 4.2 Responsibility for NDI. 7 4.2.1 Objective. 7 4.2.2 Applicability. 7 4.2.3 Elements. 7 4.2.4 Coordination. 8 4.3 Parts classification. 8 4.3.1 Structural parts classification. 8 4.3.2 Propulsion syste
10、ms parts classification. 9 4.3.3 Mechanical equipment and subsystem parts classification. 9 4.4 NDI Requirements Review Board (NDIRRB). 9 4.4.1 Purpose. 9 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B iv CONTENTS Paragraph Page 4.4.2
11、 NDI Requirements Review Board (NDIRRB) Membership. 9 5. DETAILED REQUIREMENTS FOR PRODUCTION 9 5.1 Documentation of the review. 9 5.2 Drawings. 10 5.3 Preparation of NDI procedures and process specifications. 10 5.3.1 Use of general NDI process specifications. 10 5.3.2 Company NDI process specifica
12、tions. 10 5.3.2.1 Special NDI procedures. 10 5.3.2.2 NDI standardization. 10 5.3.2.3 Approval. 10 5.3.3 NDI processes. 11 5.3.4 NDI procedures. 11 5.3.5 General NDI procedures. 12 5.4 Implementation of NDI procedures. 12 5.4.1 Personnel. 12 5.4.2 NDI reports. 12 5.4.3 Equipment and materials. 12 5.4
13、.4 NDI procedure verification. 12 5.4.5 Removal of discontinuities. 12 5.4.5.1 Reinspection. 12 5.4.6 Inspection stages. 13 5.4.6.1 First article inspections. 13 5.4.6.2 Receiving inspections. 13 5.4.6.3 Manufacturing and assembly. 13 5.4.7 Data and documentation. 13 5.4.8 Vendor qualification. 13 5
14、.4.9 Capability demonstration. 14 6. DETAILED REQUIREMENTS FOR TEST ARTICLES 14 6.1 First article testing. 14 6.2 Static test articles. 14 6.3 Component, full-scale durability test articles. 14 6.4 Teardown inspections. 14 6.5 Flight testing. 14 6.6 Test support monitoring inspections. 15 7. DETAILE
15、D REQUIREMENTS FOR SUSTAINMENT 15 7.1 Defining sustainment inspection requirements. 15 7.2 Sustainment inspection requirements review. 15 7.3 Preparation of NDI procedures. 15 7.3.1 Sustainment NDI procedure content. 15 7.3.2 Sustainment NDI procedure format. 16 7.4 Inspection capability demonstrati
16、on. 16 7.5 NDI procedure validation and verification. 16 7.5.1 Procedure validation. 17 7.5.2 Procedure verification. 17 8. NOTES 18 8.1 Intended use. 18 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B v CONTENTS Paragraph Page 8.2 Sub
17、ject term (key word) listing. 18 8.3 Changes from previous issue. 18 APPENDIX A Sample Charter for Nondestructive Inspection Requirements Review Board (NDIRRB) 19 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B 1 1. SCOPE 1.1 Scope. Th
18、is handbook provides guidance to government personnel and contractors for defining the requirements for establishing an acceptable Nondestructive Inspection (NDI) program for the development, production, and sustainment phases of DoD aircraft and missile structural components when directly reference
19、d in the item specification contract or order. This handbook is for guidance only and cannot be cited as a requirement. 1.2 Applicability. This handbook applies to structures for aircraft and missiles when the design activity or system specification requires nondestructive inspection for production
20、acceptance, and recurring nondestructive inspection for long-term sustainment. This handbook may also be applicable to mechanical equipment, subsystems and propulsion systems but the guidance should be tailored for such use. This handbook applies to all phases of the system life cycle; acquisition,
21、modification and sustainment. The NDI Program Plan should be developed at the beginning of the development phase and should define all NDI requirements to be adhered to during system development, test, production, and sustainment. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed below are n
22、ot necessarily all of the documents referenced herein, but are those needed to understand the information provided by this handbook. 2.2 Government documents. 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the ex
23、tent specified herein. DEPARTMENT OF DEFENSE SPECIFICATIONS JSSG 2006 Aircraft Structures MIL-DTL-87929 Technical Manuals, Operation and Maintenance Instructions in Work Package Format (for USAF Equipment) DEPARTMENT OF DEFENSE STANDARDS MIL-STD-867 Temper Etch Inspection MIL-STD-1530 Aircraft Struc
24、tural Integrity Program (ASIP) MIL-STD-1537 Electrical Conductivity Test for Verification of Heat Treatment of Aluminum Alloys, Eddy Current Method MIL-STD-1798 Mechanical Equipment and Subsystems Integrity Program MIL-STD-1907 Inspection, Liquid Penetrant and Magnetic Particle, Soundness Requiremen
25、ts for Materials, Parts, and Weldments MIL-STD-3024 Propulsion System Integrity Program (PSIP) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B 2 DEPARTMENT OF DEFENSE HANDBOOKS MIL-HDBK-516 Airworthiness Certification Criteria MIL-HDBK
26、-1783 Engine Structural Integrity Program (ENSIP) MIL-HDBK-1823 Nondestructive Evaluation System Reliability Assessment (Copies of these documents are available online at https:/assist.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia
27、 PA 19111-5094.) 2.2.2 Other Government documents. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. AIR FORCE - ARMY NAVY TECHNICAL MANUAL T.O. 33B-1-2/ TM 1-1500-366-23/ NAVAIR 01-1A-16-2 Nondestructive Inspection Gene
28、ral Procedures and Process Controls (Copies of this document are available from the AF NDI Office, AFRL/RXSST, 4750 Staff Dr., Tinker AFB OK 73145, DSN 339-4931 or 405-739-4931.) 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. AST
29、M INTERNATIONAL ASTM B244 Standard Test Method for Measurement of Thickness of Anodic Coatings on Aluminum and of other Nonconductive Coatings on Nonmagnetic Basis Metals with Eddy-Current Instruments (DoD Adopted) ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments (DoD Adopted)
30、 ASTM E213 Standard Practice for Ultrasonic Testing of Metal Pipe and Tubing ASTM E215 Standard Practice for Standardizing Equipment for Electromagnetic Testing of Seamless Aluminum-Alloy Tube (DoD Adopted) ASTM E309 Standard Practice for Eddy-Current Examination of Steel Tubular Products Using Magn
31、etic Saturation (DoD Adopted) ASTM E376 Standard Practice for Measuring Coating Thickness by Magnetic Field or Eddy-Current (Electromagnetic) Testing Methods (DoD Adopted) ASTM E426 Standard Practice for Electromagnetic (Eddy-Current) Examination of Seamless and Welded Tubular Products, Austenitic S
32、tainless Steel and Similar Alloys (DoD Adopted) ASTM E427 Standard Practice for Testing for Leaks Using the Halogen Leak Detector (Alkali-Ion Diode) ASTM Standard Practice for Leaks Using the Mass Spectrometer Leak Provided by IHSNot for ResaleNo reproduction or networking permitted without license
33、from IHS-,-,-MIL-HDBK-6870B 3 E498/E498M Detector or Residual Gas Analyzer in the Tracer Probe Mode (DoD Adopted) ASTM E1004 Standard Test Method for Determining Electrical Conductivity Using the Electromagnetic (Eddy-Current) Method (DoD Adopted) ASTM E1417 Standard Practice for Liquid Penetrant Te
34、sting (DoD Adopted) ASTM E1444/E1444M Standard Practice for Magnetic Particle Testing (DoD Adopted) ASTM E1742/E1742M Standard Practice for Radiographic Examination (DoD Adopted) ASTM E2033 Standard Practice for Computed Radiology (Photostimulable Luminescence Method) ASTM E2580 Standard Practice fo
35、r Ultrasonic Testing of Flat Panel Composites and Sandwich Core Materials Used in Aerospace Applications (DoD Adopted) ASTM E2581 Standard Practice for Shearography of Polymer Matrix Composites, Sandwich Core Materials and Filament-Wound Pressure Vessels in Aerospace Applications (DoD Adopted) ASTM
36、E2582 Standard Practice for Infrared Flash Thermography of Composite Panels and Repair Patches Used in Aerospace Applications (DoD Adopted) ASTM E2662 Standard Practice for Radiologic Examination of Flat Panel Composites and Sandwich Core Materials Used in Aerospace Applications (DoD Adopted) ASTM E
37、2698 Standard Practice for Radiological Examination Using Digital Detector Arrays ASTM E2736 Standard Guide for Digital Detector Array Radiology ASTM E2737 Standard Practice for Digital Detector Array Performance Evaluation and Long-Term Stability (Copies of these documents are available from www.as
38、tm.org or ASTM International 100 Barr Harbor Dr., West Conshohocken, PA 19428-2959.) AEROSPACE INDUSTRIES ASSOCIATION AIA/NAS 410 NAS Certification and Qualification of Nondestructive Test Personnel (DoD Adopted) (Copies of this document are available from www.aia-aerospace.org or Aerospace Industri
39、es Association, 1000 Wilson Blvd, Suite 1700, Arlington VA 22209-3928.) SAE INTERNATIONAL AMS2647 Fluorescent Penetrant Inspection Aircraft and Engine Component Maintenance AMS-I-83387 Inspection Process, Magnetic Rubber (DoD Adopted) Provided by IHSNot for ResaleNo reproduction or networking permit
40、ted without license from IHS-,-,-MIL-HDBK-6870B 4 AMS-STD-2154 Inspection, Ultrasonic, Wrought Metals, Process For (DoD Adopted) (Copies of these documents are available from www.sae.org or SAE World Headquarters, 400 Commonwealth Dr., Warrendale PA 15096-0001.) 3. DEFINITIONS 3.1 Inspector certific
41、ation. A written statement from the certifying agency verifying that an individual inspector has met applicable requirements. The certifying agency may be the employer of the inspection personnel. 3.2 Classification. Classification refers to functional reliability requirements of the part and implie
42、s a confidence level requirement for NDI. A high-reliability class may require redundant testing to assure adequate NDI confidence level. Complex components may be divided into zones with separate classifications. 3.3 Contracting agency. A contractor, subcontractor or Government agency procuring pro
43、duct or services. 3.4 Contractor. Organization having contractual responsibility to the Government. 3.5 Final inspection. The last inspection of a part or component usually, just prior to final acceptance. This inspection may occur during manufacturing or depot maintenance if the component will beco
44、me uninspectable at some later stage in fabrication or assembly and is not subject to reinspection, or if it is inspected just after some processing step and is not subject to reinspection by the manufacturer after further processing. 3.6 Fracture-critical part. A fracture-critical part is a safety-
45、of-flight, structural component that is not single load path nor sized by durability or damage tolerance requirements but requires special emphasis due to criticality of the component (reference MIL-STD-1530, MIL-STD-3024, MIL-HDBK-516 and JSSG 2006). 3.7 Fracture-critical traceable part. A fracture
46、-critical traceable part is a safety-of-flight structural component that is either single-load path or sized by durability or damage tolerance requirements. 3.8 Maintenance-critical part. A maintenance-critical part is a structural component whose failure will not cause a safety-of-flight condition
47、but is sized by durability requirements and would not be economical to repair or replace. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-6870B 5 3.9 Mission-critical part. A mission-critical part is a structural component in which damage or
48、 failure could result in the inability to meet critical mission requirements or could result in a significant increase in vulnerability. 3.10 Material Review Board (MRB). A government approved review of discrepant materials by authorized contractor Engineering and Quality Assurance personnel to dete
49、rmine whether material or component can be returned to an acceptable state. 3.11 Nondestructive inspection (NDI). NDI is the inspection of a structure or component in any manner that will not impair its future usefulness. The purpose of NDI may be to detect flaws at or beneath the external surface of a part, mea
