NDI cracks down on structural flaws

Published Oct. 3, 2008
By Senior Airman Clinton Atkins
379th Air Expeditionary Wing Public Affairs

Southwest Asia -- Intensely focused eyes rummage through an intricate aircraft component beneath the luminescence of a soft-glowing light inside a small compartment. The never-flinching resolve leads to a smile. "Found you," sighs the inspector.

When an aircraft or its parts' structural integrity is in question, the 379th Expeditionary Maintenance Squadron's Non-destructive Inspection Laboratory jumps into action.

"Our mission is to provide safe and reliable aircraft to the (379th Air Expeditionary Wing) and transient aircraft in the (area of responsibility)," said Master Sgt. Chad Scholl, NDI section chief, deployed from Kadena Air Base, Japan. "Our job is vital because if we didn't find fatigue cracks, disbonds and corrosion in our aging aircraft, potential lives, missions and aircraft could be lost."

The eight-man section is a 24-hour operation. In September alone the shop inspected an estimated 2,500 in-shop parts, of which three parts had structural flaws and were pulled from service. The cracks found on aircraft parts potentially saved countless lives and assets.

"One of my sayings is, 'Say no to crack,'" said Sergeant Scholl, a Garretson, S.D., native.
The NDI shop uses eddy current, X-ray, ultrasonic, penetrant, magnetic particle and optical inspection methods and also inspects engine oil lubricant for abnormal-wear metals.

"Everything we inspect is driven by technical orders and inspection techniques written by engineers," Sergeant Scholl said.

Aside from doing their indoor work, there is also scheduled and unscheduled aircraft maintenance on the flight line. Scheduled maintenance intervals for various airframes are determined by trends of past structural defects and total airframe hours.

Unscheduled maintenance occurs anytime a maintenance technician suspects a defect during a routine inspection. Some of the common inspections are aircraft skins, landing gear components and high load and vibration areas of aircraft structures.

"If a crew chief on the flight line finds what he thinks could be a crack but with the naked eye he can't tell, he will call us," he said.

"Most defective parts require extensive repair either by aircraft structural maintenance (sheetmetal) technicians or by major repair facilities, while some defects are so severe that they are condemned for service," he said.

The NDI shop provides inspection services for all assigned and transient U.S., Joint and Coalition aircraft. In-shop parts and B-1B Lancer's scheduled maintenance comprise the bulk of NDI's workload. The eight-man crew's ability to get the job done has a direct impact on the mission.

"Every minute we're late getting to an aircraft can be seen at the tail end when the troops on the ground need that bomber or an aircraft needs gas," Sergeant Scholl said. "Whenever there is a job (on the flight line) for the 379 AEW we have to be out there immediately to get the job done so the aircraft can get in the air."

Recently, the fleet of Royal Australian Air Force's C-130J Hercules assigned here were grounded for a problem found during an inspection.

According to the RAAF, the NDI shop shortened the fleet's grounding period by several days.

"Without (NDI's) help we would have had to reach back to Australia and send a technician which would have taken two weeks or more," said RAAF Wing Commander Peter Ward.

As part of a central intermediate repair facility in the 379 EMXS, NDI also inspects parts from all around the AOR.

"We inspect wheel and brake assemblies from all over the AOR that are sent to the 379 EMXS," he said.

After the wheels and brakes go through various different shops to disassemble, remove the paint and clean, NDI inspects each part before they are painted again.

"They're pretty limited on resources up range so we end up seeing a lot of parts," he said. "The CIRF program also allows bases in the AOR to have less of a deployed footprint."

When the customer is in the AOR, there's no room for complacency, he said.

"Doing the same work day after day you can never be relaxed," he said. "We have to bring our 'A-game' every time we do an inspection."

Sergeant Scholl reminds his Airmen of the dangers of becoming too relaxed while accomplishing NDI inspections.

"It is very important that NDI technicians receive proper training and maintain good inspection habits," said Sergeant Scholl.

Senior Airman Tysean Wilson, who is on his first deployment, heeds his section chief's warning.

"I try to learn something new everyday, that way my mind will be fresh," said the Yuba City, Calif., native deployed from Langley Air Force Base, Va. "This place isn't a training base so you have to hit the ground running."

Their job may seem small, but when put under a microscope it is plain to see what these Airmen do saves lives.

"The greatest satisfaction I get from my job is knowing aircraft are safe, reliable and they can drop bombs, haul cargo, pump gas and execute their missions. We are directly responsible for someone's life and I take it to heart." Sergeant Scholl said.