DI-SESS-82268
Aircraft Structural Teardown Inspection and Evaluation Report
Describes the teardown inspection and evaluation procedures, processes, and results for all lifecycle phases of an aircraft structural teardown program.
Approval DateMay 17, 2019
AMSC NumberF10033
Preparing Activity11 (AFLCMC/EZFS)
Project NumberSESS-2019-015
OPR—
DTIC ApplicableNo
GIDEP ApplicableNo
Limitation—
Applicable Forms—
Approval Limitation—
Form Version—
DID Formatfree_text
963C CompliantYes
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
Supersedes
—Related
—Description & Purpose
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Application & Interrelationship
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Use & Relationship
The Aircraft Structural Teardown Inspection and Evaluation Report describes the teardown inspection and evaluation procedures, processes, and results for all lifecycle phases of a program.
a. The report shall describe the teardown data management system used to identify, track, and electronically document the five primary teardown execution elements: extraction, disassembly, coating removal, nondestructive inspection (NDI), and failure analysis. The report shall describe the results of all NDI findings and any supporting failure analysis and root cause evaluation activities.
b. This Data Item Description (DID) contains the format, content, and intended use information for the data deliverable resulting from structural teardown inspections, including the work tasks described by Tasks III and V of MIL-STD-1530, Aircraft Structural Integrity Program (ASIP). (Copies of the document are available online at https://quicksearch.dla.mil.)
Preparation Instructions
1Reference documentsThe applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.
2FormatThe report shall be in the contractor's format.
3ContentThe report shall include the following information:
3.1Photographs and descriptions of the aircraftPhotographs and descriptions of the aircraft, to include: its model number, production date, applicable engineering changes (e.g., deviations from operational configuration), and testing and service history.
3.2Descriptions of the teardown data management systemDescriptions of the teardown data management system that serves as the permanent electronic record of the entire teardown inspection and evaluation program, and that provides the ability to create and maintain continuity of data visibility and control through every stage of the program. The report shall include descriptions of the processes and protocols for electronic photographic and records entry into the teardown data management system for documenting data, findings, and analysis throughout all lifecycle phases of the program. The report shall document the processes for identifying and tracking:
3.2.1Teardown sections, parts, and sub-parts
3.2.2Disassembly procedures and protocolsDisassembly procedures and protocols for each section, part, and sub-part.
3.2.3Required NDI and failure analysisRequired NDI and failure analysis for each teardown section, part, and sub-part.
3.2.4All teardown, NDI, and failure analysis data and resultsAll teardown, NDI, and failure analysis data and results, to include: supporting files and photographs for all protocols.
3.2.5Teardown, NDI, and failure analysis statusTeardown, NDI, and failure analysis status for each section, part, and sub-part.
3.3Descriptions of the processes for ensuring accurate teardown component identificationDescriptions of the processes for ensuring accurate teardown component identification and continuous tracking throughout the teardown inspection and evaluation program. The report shall document the protocols and methods for:
3.3.1Specifying the standard convention for establishing and maintaining unique identificationSpecifying the standard convention for establishing and maintaining unique identification for all lots, teardown sections, parts, and sub-parts.
3.3.2Section, part, and sub-part physical identification marking, tagging, and labelingSection, part, and sub-part physical identification marking, tagging, and labeling throughout the teardown and failure analysis processes.
3.3.3Electronic photographic and records entryElectronic photographic and records entry into the teardown data management system for component identification and tracking.
3.4Descriptions of the protocols for performing teardown section extractionDescriptions of the protocols for performing teardown section extraction that removes structural parts and assemblies while preventing incidental damage. The report shall document the processes for:
3.4.1Accurately locating the physical extent or boundaries of designated teardown sectionsAccurately locating the physical extent or boundaries of designated teardown sections, to include: application of extraction cut line markings (if authorized), component identification, orientation, and aircraft coordinate reference marks to the designated teardown section prior to extraction.
3.4.2Documentation of repairs and anomaliesDocumentation of repairs; loose fasteners; missing fasteners; missing fastener elements; corrosion; paint, coating, and material conditions; gouges; chafing; cracking; or any other anomalies on the surface of the teardown section.
3.5Descriptions of the protocols for conducting precision parts and sub-parts disassemblyDescriptions of the protocols for conducting precision parts and sub-parts disassembly in a deliberate and organized manner that minimizes damage induced by disassembly. The processes for documenting observed damage, cleaning parts, removing all mechanical fasteners, and removing all sealants shall be documented in the report.
3.6Descriptions of the part coating removal processDescriptions of the part coating removal process that prevents substrate material damage in order to optimize NDI results. The report shall describe the coating removal system for each coating type, to include: removal chemicals, holding containers, part removal tools, any heating or circulation elements, rinsing items, and post-coating removal storage to prevent environmental corrosion.
3.7Descriptions of corrosion preventive compound (CPC) evaluation processesDescriptions of corrosion preventive compound (CPC) evaluation processes to determine whether CPC application helped to mitigate corrosion (if applicable). The report shall include documentation of article repairs; loose fasteners; missing fasteners; missing fastener elements; corrosion; paint, coating, and material degradation; gouges; chafing; and cracking.
3.8Descriptions of the NDI proceduresDescriptions of the NDI procedures that are used to interrogate sections, parts, sub-parts, and materials for discontinuities, defects, and damage without causing damage to a component or resulting in loss of vital metallographic grain structure and crack face microstructure evidence. For each NDI indication, the report shall include descriptions of the full extent of the observed damage, indication details, the suspected source of the indications, the NDI methods used, and any other relevant descriptors used by NDI inspectors to help quantify the strength of the indications.
3.9Descriptions of the protocols for specimen sectioning and related metallurgical evaluationDescriptions of the protocols for specimen sectioning, mounting, polishing, crack opening, fracture surface examination and characterization, corrosion type identification, corrosion product identification, fracture surface corrosion product removal, corrosion grindout evaluation, and related metallurgical evaluation (alloy and temper identification). The report shall describe the results of the failure analysis and root cause analysis for NDI indications for each specimen, to include:
3.9.1A description of the NDI indication which resulted in the requirement for a failure analysis investigationA description of the NDI indication which resulted in the requirement for a failure analysis investigation, including: the precise structural location and pertinent NDI details.
3.9.2A summary of the failure analysis investigationA summary of the failure analysis investigation by detailing the methodology, the failure analysis tools used, a summary of the analysis performed on the indication, and finding results.
3.9.3The macroscopic indication and finding imagesThe macroscopic indication and finding images to include detailed photographs of the indication prior to beginning destructive failure analysis and a finding and analysis schematic.
3.9.4Data and evidence that supports the findingData and evidence that supports the finding that shall include (if applicable):
3.9.4.1Enhanced visual images of the finding at the indication site
3.9.4.2Micrographs of the sectioned part showing the damage, if any
3.9.4.3Elemental analysis plot from energy-dispersive X-ray spectroscopy (EDXS)
3.9.4.4Scanning electron microscope (SEM) imagesScanning electron microscope (SEM) images of:
3.9.4.4.1The opened fracture surface with clearly identified fracture surface features
3.9.4.4.1.1Striation measurement sites, if applicable
3.9.4.4.1.2Initiating feature(s), if applicable
3.9.4.5X-ray computed tomography or ultrasonic images
3.9.4.6Digital imagery from any technique
3.9.4.7Geolocation information
3.9.5Programmatic informationProgrammatic information, to include:
3.9.5.1The vendor conducting the failure analysis investigations
3.9.5.2The names of the investigator and senior metallurgist who validated each failure analysis investigation
3.9.5.3The contact information for the investigator and the senior metallurgistThe contact information for the investigator and the senior metallurgist who conducted the failure analysis investigations.
3.9.5.4The completion date and expenditure detailsThe completion date and expenditure details for each failure analysis investigation.
3.9.5.5The teardown program name
References
MIL-STD-1530, Aircraft Structural Integrity Program (ASIP) https://quicksearch.dla.mil
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