Eddy Current Array Inspection of Aluminum Aircraft Skins using an Automated Crawler

In-service aircraft structure, such as fuselage or wing skins, experience damage or degradation during their lifetime.  Instrument-based Nondestructive Inspection (NDI) is generally mandated to quantify the damage and determine the appropriate maintenance response.

Currently, the NDI methods utilized for in-service structural inspection are mostly hand-held, particularly for commercial aircraft. These methods are labor-intensive, time-consuming, and provide minimal, if any, long-term tracking capability for features or damage. NDI scanning systems, like the Boeing MAUS (Mobile Automated Scanner) are utilized at the military depot or MRO (Maintenance, Repair & Overhaul) level. While these provide obvious improvements in inspection speed and data quality, they still require significant human activity for scanner attachment/detachment and movement, and personnel lift positioning for access to the structure.

Automated NDI (AuNDI) is a new approach to NDI, where robotic crawlers replace current methods of system and sensor placement and scanning. The goal of AuNDI is eliminating the human interaction in the data collection process, and eventually, the analysis process as well. AuNDI has the potential to reduce labor costs and inspection times, provide improved data quality, and support ongoing maintenance management. It also ensures a safer working environment for inspection personnel and reduces the potential for damage to the aircraft during inspection.

Boeing is currently developing AuNDI technologies to address current and future commercial and military aircraft inspection needs. This presentation will describe the general elements that go into an AuNDI system for conducting eddy current inspection of aluminum aircraft fuselage skins.