Nondestructive testing of commercial airplane composite wing tip components

The Boeing 767-400ER is an extended range airplane that is built with a wing tip that sweeps back at a different angle then the rest of the wing. This wing tip is approximately 3.5m (11 feet) long and is built using composite parts that need to be inspected using ultrasonic nondestructive testing (NDT). This new product was introduced into an operating factory using existing immersion tanks normally used to inspect the Boeing 777 empennage composite detail parts. The wing tip components are constructed out of carbon fiber epoxy pre-impregnated fabric and Nomex honeycomb core. The detailed parts are inspected with 1 and 5 MHz through transmission inspection (TTU). One of the spars has a joggle running length wise down the flange. Special probe and inspection techniques were developed to inspect this area. Because of the difficulty in inspecting the skin panels with existing equipment, a TTU squirter system was developed that worked on another existing scanner. This change was made to reduce handling time and improve safety. This new product was inspected on specialized equipment with very little modification.