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Type of Damage

The document defines various types of surface imperfections and damage that can occur to parts including abrasions, buffing, burnishing, burrs, dents, impressions, nicks, polishing, scratches, surface imperfections, surface texture, swaging, tooling marks, chatter marks, external features, gouges, imperfections, internal features, major flaws, minor flaws, pinched surfaces, pitting, and raised material. It provides descriptions of dents, nicks, scratches, cracks, holes, abrasion, gouges, corrosion, delamination, and disbonds.

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121 views

Type of Damage

The document defines various types of surface imperfections and damage that can occur to parts including abrasions, buffing, burnishing, burrs, dents, impressions, nicks, polishing, scratches, surface imperfections, surface texture, swaging, tooling marks, chatter marks, external features, gouges, imperfections, internal features, major flaws, minor flaws, pinched surfaces, pitting, and raised material. It provides descriptions of dents, nicks, scratches, cracks, holes, abrasion, gouges, corrosion, delamination, and disbonds.

Uploaded by

handoko
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Abrasion: Surface imperfection that doesn’t remove or displace material

appears as ascuff or a change to the surface finish.


Buffing: Light polishing with a soft cloth or cloth wheel
Burnishing: Light material rubbing; burnishing produces a “smoothing” of
material and a shiny outer surface. Material removal does not occur.
Burrs: Sharp edges around the part features, often caused by manufacturing
processes like punching, shearing, milling or drilling.
Dents and Dings: Any small, measurable depression in a part surface, often
produced by striking or pressing the surface.
Impressions: A mark or blemish made by pressure. An impression could be a
ding or dent.
Nick: A slight cut, chip, or indentation on a surface or edge.
Polishing: To remove roughness from a surface and make it smooth by
rubbing, with or without compound.
Scratches: Lines or marks on a surface, often created by a sharp object. A
scratch is defined as a maximum of .003in.in width, and by nature, a scratch
involves the removal or displacement of material.
Surface Imperfections and/or Flaws: Surface interruptions such as cracks,
nicks, Dings, Dents, scratches or ridges.
Surface Texture: Describes geometric irregularities of the surface of a solid
material.
Swaging: A cold working process for shaping material, where material is
forced into a die(s) using continuous, repeated impacts.
Tooling Marks: Any marks that appear on the surface of a part as the result of
a manufacturing process, including, but not limited to: depressions, gouges,
impressions, clamping marks, etc.
CHATTER/CHATTER MARKS:A pattern of undulations introduced on a machined surface by
intermittent loading as a result of vibration on the work piece, cutting tool, grinding wheel,etc
EXTERNAL FEATURE:Feature on the part being delivered to a Lisk customer which is visible
without disassembly.
GOUGE: A wide, rough scratch or group of scratches, usually with one or more sharply
impressed corners, and frequently accompanied by deformation or removal of parent material.
IMPERFECTION: Unintentional, and unexpected interruptions in the part surface texture. Not
all imperfections are FLAWS; for example, a surface specified as a 63 Ra, and is generally
manufactured as an 8 Ra, except in small zones that are a 60 surface texture. Thus some
imperfections are NOT drawing violations.
INTERNAL FEATURE:
A feature on the part that is not visible to the customer without disassembly.
MAJOR FLAW: A flaw which does not meet the requirements of this document. A flaw is
included in the surface finish measurement.
MINOR FLAW: A flaw which is acceptable per the requirements of this document. A flaw is
included in the surface finish measurement.
PINCHED: Distortion of one or more surfaces of the parent material, caused by pressure.
PITTING: Small crater looking appearance typically caused by oxidation of the base material.
RAISED MATERIAL: Any material that protrudes above the parent surface or pad

Dent: A Dent is depressed or hollow deformations without removal of material or change in cross sectional
area (see scratch & crack definition below). Stress wrinkles caused by  failure of a fastener are not
considered a dent.   Generally dents are caused by impact from a smoothly contoured object.  One
characteristic that all dents should have is a "pushed in surface" and a relatively  smooth bottom where
metal is not displaced,  folded or creased. Many Aircraft Structural Repair Manuals specify that a "crease"
be treated as a crack. Generally when evaluating dents, the width of the dent is the second longest distance
across the dent, measured at 90 degrees to the direction of the length.

Nicks: Broken edges without cracks, but with portions of material removed. Negligible damage limits will
vary with structure, material, and loading.

Scratches: Marks penetrating the surface that reduce the structural cross section of the material but do not
penetrate the complete thickness. The depth of a scratch may be determined by use of an optical
micrometer. Generally, scratches in  Alclad aluminum alloy sheet that do not penetrate the protective
Alclad layer are classified as negligible.

Cracks: Fractures that would not separate the material into two parts if the surrounding supports were
removed; usually originating at edges, holes, or points where concentrated loads are applied or where abrupt
changes in cross-sectional area occur. Cracks cause a significant cross-sectional area change. This damage
usually has an irregular line and is often the result of fatigue in the material. The length of cracks that may
be tolerated varies widely with material, structure, and application. No crack should be regarded as
negligible until the damage limits for the affected structure have been determined.

Holes:  Punctures, penetrations or cutouts that breach the complete thickness of the material and is fully
surrounded by undamaged material.The size, shape, and distance from edges and supporting structures must
be considered when evaluating hole damage.

Abrasion:  A damaged area that is the result of scuffing, rubbing, scraping, or other surface erosion. This
type of damage is usually rough and has an irregular shape.

Gouge: A damaged area where the result is a cross-sectional change caused by a sharp object and gives a
continuous, sharp or smooth groove in the material

Corrosion:  Deterioration of a metal because of an electrochemical reaction with its environment.


Depending on the type of corrosion, this deterioration may take the form cracking, exfoliation, or erosion
of the corroding material. Corrosion damage is typically classified as light, moderate, or severe,depending
on the extent of the corrosion and the loading requirements of the corroded part. Aircraft-specific structural
manuals should be consulted for the correct classification of corrosion damage on a given part.
Note: An initial accurate  determination of the type of damage encountered can usually be  made by the use
of a 10X magnifying glass or an optical micrometer.  True crack length determination will generally require
some form of Non Destructive Testing such as Eddy Current or Fluorescent penetrants .

Delamination: Separation of the layers of material in a laminate, either local or covering a wide area, that
occurs during manufacturing or in service. Fiber-reinforced and composites may delaminate when impacted
and not exhibit visible damage.

Disbonds: An area within a bonded interface between two adherents in which an adhesion failure or
separation has occurred. If the separation is performed deliberately to referred to as a debond.

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