Use of robotics in nondestructive inspection

Until very recently, nondestructive inspection of aircraft components at McClellan Air Force Base had been done in the traditional way. Ultrasonic inspections have been performed using hand-held equipment. X-ray inspections were performed using film radiography with the x-ray tubes being held on cradles, tripods, or suspended from pendant-operated or manual overhead crane-type fixtures. Implementation of advanced ultrasonic and real-time x-ray systems required that new equipment handling and parts handling methods be devised. Aircraft flight safety considerations demanded that neutron radiography be implemented as an inspection technique in order to find low levels of moisture and corrosion in the F-111 aircraft structure and aerodynamic surfaces. Traditional nondestructive inspection (NDI) methods require removal of suspect panels from the aircraft, including some panels that were not designed to be removed. The solution to these problems was to implement NDI systems that would allow inspection of intact aircraft. A new NDI facility especially designed for the latest in technology is under construction. It will house two large maneuverable x- and n-ray systems. The ∼ 90-ft-span gantry robots will scan intact aircraft with real-time x-ray and near real-time n-ray systems. A unique floor/rail-mounted n-ray system will automatically inspect the F-111 aircraft engine bays