Inspect Complex Non Metallic Manufactured Components And Assemblies Training

Objectives:
• Understand the scope and importance of inspecting non-metallic components.
• Identify common non-metallic materials used in manufacturing.
• Explain basic inspection principles and terminology.
• Recognise the role of quality assurance in manufacturing.

Topics:
• Overview of non-metallic materials: polymers, composites, ceramics, elastomers.
• Manufacturing processes for non-metallic components.
• Introduction to inspection: purpose, types (visual, dimensional, NDT).
• Quality management systems and standards (ISO 9001, AS9100).
• Safety practices in inspection environments.

Objectives:
• Describe key physical and mechanical properties of non-metallic materials.
• Understand how processing affects material integrity.
• Identify common defect types and their causes.
• Relate material behaviour to inspection requirements.

Topics:
• Mechanical properties: strength, stiffness, hardness, toughness.
• Thermal properties: glass transition temperature, thermal expansion.
• Defect mechanisms: voids, cracks, delamination, inclusions.
• Effects of moisture, UV, and chemical exposure.
• Case studies of material failures.

Objectives:
• Perform visual inspections according to standard procedures.
• Use appropriate lighting and magnification tools.
• Document visual findings accurately.
• Identify surface and subsurface indications.

Topics:
• Principles of visual inspection.
• Tools: borescopes, magnifiers, mirrors, gauges.
• Lighting techniques for different materials.
• Acceptance criteria for surface defects.
• Recording and reporting visual results.

Objectives:
• Select and use measurement instruments correctly.
• Perform dimensional measurements on complex geometries.
• Interpret engineering drawings and tolerances.
• Apply statistical process control basics.

Topics:
• Measurement tools: callipers, micrometres, height gauges, CMM.
• Reading engineering drawings and GD&T symbols.
• Measurement uncertainty and calibration.
• Data collection and analysis.
• Introduction to SPC and control charts.

Objectives:
• Explain ultrasonic wave propagation in non-metallics.
• Set up UT equipment for basic inspections.
• Identify echoes and interpret A-scans.
• Understand limitations of UT on non-metallics.

Topics:
• Principles of ultrasonic testing.
• Transducers and couplants for non-metallic materials.
• Calibration using reference standards.
• Flaw detection and sizing.
• Advantages and challenges for composites and polymers.

Objectives:
• Conduct UT inspections on sample components.
• Differentiate between flaw types and geometric reflections.
• Record and evaluate test results.
• Apply acceptance criteria.

Topics:
• Hands-on UT scanning techniques.
• Thickness measurement on non-metallics.
• Detecting delaminations, voids, and disbonds.
• Using DGS/AVG diagrams.
• Practical exercises with composite panels.

Objectives:
• Understand X-ray and gamma ray principles.
• Identify radiographic image features.
• Apply radiation safety procedures.
• Interpret radiographs of non-metallic components.

Topics:
• Basic physics of radiography.
• Film and digital radiography systems.
• Image quality indicators (IQI).
• Safety: ALARA, dosimetry, shielding.
• Interpretation of porosity, inclusions, cracks.

Objectives:
• Set up and expose radiographs on sample parts.
• Process and evaluate radiographic images.
• Identify and report discontinuities.
• Comply with safety protocols.

Topics:
• Hands-on exposure setup for composites.
• Film processing or digital image acquisition.
• Viewing conditions and interpretation.
• Reporting defects per standards.
• Practical exercises with various thicknesses.

Objectives:
• Explain the principles of liquid penetrant testing.
• Perform PT on non-metallic surfaces.
• Interpret indications correctly.
• Understand limitations for porous materials.

Topics:
• PT process: pre-cleaning, application, dwell, removal, developer.
• Types of penetrants: visible, fluorescent.
• Surface preparation for non-metallics.
• Evaluation of indications.
• Safety and environmental considerations.

Objectives:
• Understand MT applicability to non-metallics (limited).
• Learn eddy current principles for conductive non-metallics.
• Perform basic ET inspections.
• Compare methods for different materials.

Topics:
• MT principles and limitations for non-ferrous.
• Eddy current theory and probe selection.
• ET for carbon fibre composites.
• Conductivity measurements.
• Case studies: detecting impact damage.

Objectives:
• Describe active and passive thermography.
• Interpret thermal images for defects.
• Understand shearography principles.
• Apply these NDT methods to composites.

Topics:
• Infrared thermography: heat sources, cameras.
• Detecting delaminations and moisture ingress.
• Shearography: laser interferometry.
• Vacuum and thermal stressing.
• Practical demonstrations.

Objectives:
• Explain acoustic emission principles.
• Set up AE sensors on non-metallic structures.
• Perform leak testing on assemblies.
• Interpret AE data for damage monitoring.

Topics:
• AE sources in composites: matrix cracking, fibre breakage.
• Sensor placement and frequency selection.
• Leak testing methods: bubble, pressure decay, tracer gas.
• Data analysis and source location.
• Applications in pressure vessels and piping.

Objectives:
• Perform tensile, flexural, and hardness tests.
• Prepare specimens per standards.
• Analyse test results for material quality.
• Relate destructive results to NDT findings.

Topics:
• Tensile testing of polymers and composites.
• Flexural and compression tests.
• Hardness tests: Shore, Barcol.
• Specimen preparation and conditioning.
• Correlation with NDT data.

Objectives:
• Apply NDT methods to bonded and bolted assemblies.
• Inspect honeycomb and sandwich structures.
• Detect disbonds and core damage.
• Evaluate assembly integrity.

Topics:
• Bondline inspection using UT and thermography.
• Bolt torque verification and hole quality.
• Honeycomb core: water ingress, crush.
• Adhesive joint evaluation.
• Practical inspection of a composite assembly.

Objectives:
• Inspect injection-moulded and extruded parts.
• Identify common defects: sink marks, flash, voids.
• Assess rubber components for hardness and cracking.
• Apply relevant standards.

Topics:
• Moulding defects and their causes.
• Dimensional checks on plastic parts.
• Elastomer testing: compression set, ozone resistance.
• Visual and UV inspection for cracks.
• Standards: ASTM, ISO, SANS.

Objectives:
• Understand brittle material failure modes.
• Perform visual and NDT on ceramics.
• Inspect glass components for stress and flaws.
• Apply statistical methods for strength.

Topics:
• Ceramic defects: porosity, cracks, inclusions.
• Ultrasonic testing of ceramics.
• Polariscope for glass stress analysis.
• Weibull statistics for brittle materials.
• Practical inspection of ceramic insulators.

Objectives:
• Write clear inspection reports.
• Maintain traceability of components.
• Use non-conformance reporting systems.
• Understand record-keeping requirements.

Topics:
• Inspection report structure and content.
• Non-conformance reports (NCR) and corrective actions.
• Traceability: batch numbers, serialisation.
• Digital documentation systems.
• Legal and contractual implications.

Objectives:
• Apply quality management principles.
• Conduct internal audits of inspection processes.
• Identify improvement opportunities.
• Understand accreditation and certification.

Topics:
• ISO 9001 and AS9100 requirements for inspection.
• Audit planning and checklists.
• Corrective and preventive actions.
• Personnel certification (PCN, ASNT).
• Laboratory accreditation (ISO 17025).

Objectives:
• Explore advanced NDT techniques.
• Understand digital radiography and CT scanning.
• Discuss automated inspection systems.
• Evaluate new methods for complex geometries.

Topics:
• Computed tomography (CT) for internal structures.
• Phased array ultrasonic testing (PAUT).
• Laser ultrasonics and air-coupled UT.
• Robotic inspection systems.
• Industry 4.0 and data analytics.

Objectives:
• Demonstrate competency in multiple inspection methods.
• Inspect a complex non-metallic assembly.
• Produce a comprehensive inspection report.
• Review key concepts and address gaps.

Topics:
• Practical assessment: inspect a composite component using UT, PT, and visual.
• Dimensional measurement and report writing.
• Oral review of findings.
• Course summary and Q&A.
• Feedback and certification guidance.