Lichfield-based process system specialist George Koch Sons Europe Ltd (www.kochllc.com) has completed a multi-stage penetrant-based flaw detection facility for Airbus UK.

The self-contained installation is now a key element in the manufacture of Airbus wings and associated components.

Steve Moseley, sales manager at George Koch, said: “Airbus’s move from chromic acid-based chemical solutions to tartaric sulphuric acid meant that the original visual inspection method for crack detection could no longer be used.

"The use of fluorescent penetrant-dye inspection was considered the most appropriate alternative — the procedure being centred on the application of fluorescent penetrant spray and developer powder, followed by a detailed UV inspection.”

Because of space restrictions at the site, George Koch’s solution was to build a single self-contained PFD inspection chamber to house the 11 separate stages of the process and shut out all ambient light.

The relevant process nozzles and applications are presented to each component as it proceeds through the chamber on a gantry.

Mr Moseley added: “The final stage sees the UV lighting for the penetrant dye being assessed by specialist operators — a procedure that is optimised by the enclosed configuration.

“Any potential defects are revealed as fluorescent indications.”