AERO ENGINE REPAIR AND

MAINTENANCE
SCHOOL OF AERONAUTICAL SCIENCES
HINDUSTAN UNIVERSITY

AE 1317 MANUAL
 HINDUSTAN INSTITUTE OF
TECHNOLOGY AND SCIENCE
SCHOOL OF
AERONAUTICAL ENGINEERING

AE 1317
AERO ENGINE REPAIR AND
MAINTENANCE
LAB MANUAL

1
SL.NO DESCRIPTION PAGE
NO
INTODUCTION TO PISTON
1
ENGINE
DISMANTLING OF PISTON
2
ENGINE
VIEWING PROCEDURE AND
DIMENSION CHECKING OF
a. CLINDER BLOCK
3 b. CRANK SHAFT
c. CAMSHAFT
d. CONNECTING ROD
e. PISTON ASSEMBLY
REASSEMBLY OF PISTON
4
ENGINE
INTRODUCTION TO JET
5
ENGINE
6 DISMANTLING OF JET ENGINE
7 REASSEMBLY OF JET ENGINE
8 PROPELLER PITCH SETTING
ENGINE STARTING
9
PROCEDURE
10 NON DESTRUCTIVE TESTING

2
INTRODUCTION TO PISTON ENGINE

Engine is a device which converts chemical energy of fuel into thermal

and to mechanical energy. A piston engine, is a heat engine that uses one or
more reciprocating pistons to convert pressure into a rotating motion. In
most types, the linear movement of the piston is converted to a rotating
movement via a connecting rod and a crankshaft mechanism.

VARIOUS TYPES OF PISTON ENGINES:

1. In-line engine
2. V-type engine
3. Radial engine
4. Horizontally opposed engine

MAJOR COMPONENTS

CYLINDER

A cylinder is the central working part of a reciprocating engine the space

in which a piston travels. Multiple cylinders are commonly arranged side by
side in a bank, or engine block, which is typically cast from aluminum or
cast iron before receiving precision machine work. Cylinders may be sleeved
(lined with a harder metal) or sleeveless (with a wear-resistant coating such
as Nikasil).

PISTON

A piston is a component of reciprocating engines, reciprocating pumps,

gas compressors and pneumatic cylinders, among other similar mechanisms.
It is the moving component that is contained by a cylinder and is made gas-
tight by piston rings. In an engine, its purpose is to transfer force from
expanding gas in the cylinder to the crankshaft via a piston rod and/or
connecting rod. In a pump, the function is reversed and force is transferred
from the crankshaft to the piston for the purpose of compressing or ejecting

3
 the fluid in the cylinder. In some engines, the piston also acts as a valve by
covering and uncovering ports in the cylinder wall.

Material

Pistons are cast from aluminium alloys.

CRANK SHAFT

The crankshaft, sometimes casually abbreviated to crank, is the part of an

engine that translates reciprocating linear piston motion into rotation. To
convert the reciprocating motion into rotation, the crankshaft has "crank
throws" or "crankpins", additional bearing surfaces whose axis is offset from
that of the crank, to which the "big ends" of the connecting rods from each
cylinder attach.

Material :

Crankshafts can be forged from a steel bar usually through roll forging or
cast in ductile steel. With forged crankshafts, vanadium micro alloyed steels

CAM SHAFT

In internal combustion engines with pistons, the camshaft is used to

operate poppet valves. It then consists of a cylindrical rod running the
length of the cylinder bank with a number of oblong lobes protruding from
it, one for each valve. The cams force the valves open by pressing on the
valve, or on some intermediate mechanism as they rotate. The relationship
between the rotation of the camshaft and the rotation of the crankshaft is of
critical importance. Since the valves control the flow of the air/fuel mixture
intake and exhaust gases, they must be opened and closed at the
appropriate time during the stroke of the piston. For this reason, the
camshaft is connected to the crankshaft either directly, via a gear
mechanism,

4
Material

Chilled iron castings:

Billet Steel:

CONNECTIONG ROD

In a reciprocating piston engine, the connecting rod or conrod connects

the piston to the crank or crankshaft. Together with the crank, they form a
simple mechanism that converts linear motion into rotating motion. The
usual solution for high-performance aero-engines is a "forked" connecting
rod. One rod is split in two at the big end and the other is thinned to fit into
this fork. The journal is still shared between cylinders. The Rolls-Royce
Merlin used this "fork-and-blade" style.

VALVES:
In general a valve is a device for regulating or determining the check
on the flow of a liquid or a gas by a movable part which opens or closes into
a passage. The main purpose of a valve in IC engine is to open and close
parts which are into the combustion chamber of the engine namely intake
and exhaust ports. The valves are associated with valve guides,valve seats
and valve springs.

PROPELLERS:
They are essential aircraft parts that provide the necessary
thrust for moving the aircraft. The propeller is connected to the engine by
means of a shaft. The propeller consists of two or more blades and a central
hub to which the blades are attached.
Engines and their components are designed and built to provide
many years of service. For an aircraft to remain in an airworthy condition
the following conditions have to be fulfilled.

5
EXP NO.01 STRIPPING OF PISTON ENGINE

AIM:

To dismantle a piston engine and study its particular components.

TOOLS REQUIRED:

Special tools for notching crank shaft.

Universal socket for spark plug
Selected spanner no: 6-19
Ring spanner no: 6-22
Adjustable spanner
Plier, cutter and screwdriver
Value depression tool
Crow foot spanner

PROCEDURE:

1. Remove spark plug and rocker curves.

2. Remove starter and accessories.
3. Turn the engine over such that cylinders are upper most.
4. Remove controls completely with universal joints.
5. Remove air scoop, plug leads, distribution covers.
6. Remove induction system with carburetor.
7. Unscrew push rod ball socket from rockers.
8. Take out push rod and push rod covers.
9. Remove cylinder baffle plate.
10. Remove cylinder.
11. Remove piston rings.
12. Extract gudgeon pin, air clip.
13. Withdraw gudgeon pin and piston. Remove magnetos.
14. Remove gearbox with timing gear cover.
6
 15. Turn the engine cover on its stand. Remove starter.
16. Remove adaptor, thrust bearing cover and top cover.
17. Detach big and bearing caps. Withdraw connecting rod.
18. Remove main, intermediate bearing caps.
19. Lift crankshaft. Unscrew idle gear hub bolt.
20. Draw off gear wheel. Remove magneto drivers.
21. Unscrew camshaft gagging the gear.
22. Remove camshaft rear bearing bush.
23. Withdraw camshaft. Remove tappet and guides.
24. The parts are kept for visual inspection.

RESULT:

Thus the stripping of piston engine is carried according to instructions

in the manufacturer’s maintenance manual.

7
8
CYLINDER BLOCK

9
EXP.NO.02
A. VIEWING PROCEDURE - CYLINDER BLOCK

AIM:

To perform maintenance and inspection checks on CYLINDER BLOCK of

Piston Engine

CYLINDER HEAD:-

TOOLS REQUIRED:

a) Dip Basket
b) Stud removal tool
c) Spark Plug insert tool
d) Hand Brace with drill bit
e) Drifts
f) Bore Gauge
g) Magnifying Glass

PROCEDURE:-

Cleaning:-

Clean the cylinder head with petroleum solvent and dip it in the
petroleum agent using the cleaning basket.

Visual Inspection:-

1. Inspect the cylinder head visually using magnifying glass and a

powerful light source for loose, scored pitted or damaged valve
seat.

2. Similarly ,inspect the cylinder head for

a. Loose damaged studs- replace with suitable new studs

10
 b. Loose damaged spark plug inserts replace with oversize
inserts
c. Loose, cracked valve guides.
d. Damaged mounting ports, intakes, exhaust, rocker box
covers
e. Cracked/damaged cooling fins-crack is stopped by drilling a
3/16” dia hole through the end of the crack. This is
permissible provided the end of the crack is at least ¼” from
the base metal

Dimension Check:-

a) Check the internal diameter of the intake and exhaust valve

guides with a flat plug rejection gauge.
b) Check the diameter and roundness of the guide bore with
the gauges.
c) Check the wear and tear in the rocker arm bush.
d) All the above dimensions are measured using precision
instruments.

CYLINDER BARREL:-

Tools required:-

1. Cleaning Basket
2. Feeler Gauge
3. Dial Gauge
4. Bore Gauge

11
PROCEDURE:-
Cleaning:-

Clean the cylinder barrel with petroleum solvent and dip it in the
petroleum agent using the cleaning basket.

Visual Inspection:-

Inspect the barrel visually for general flaws, cracks and conditions

1. Cooling fins-check for nicks and notches for needed profile with
a hand grinder or file
2. Barrel-check for cracks which may be a cause for rejection
3. Skirt-check cracks, bends and breaks to hamper proper
operation
4. Mounting flange-check for cracks, nicks and warping
5. Inside Barrel- inspect for scoring, corrosion etc. Honing can be
done for minor repairs

Dimensional checks:-

1. Fit between piston and cylinder, maximum clearance between

piston skirt and cylinder is 0.021” loose.
2. Maximum taper of cylinder wall is 0.018”
3. Maximum ovality is 0.018”

RESULT:-

Thus an inspection of the cylinder assembly has been carried out

as per given inspection manual.

12
CRANK SHAFT

13
 2B. VIEWING PROCEDURE - CRANK SHAFT

AIM:

To view the crankshaft and check out its dimensions.

TOOLS REQUIRED:

a. Surface table
b. V-block
c. Dial indicator
d. Vernier caliper
e. Micrometer
f. Magnifying glass

PROCEDURE:

a. Check for cracks by contact current method.

b. Check for corrosion, pitting etc..
c. Check for ovality and taperness using micrometer.
d. Check external dimensions of crank pin and journals.
e. Carry out rip check before measuring internal dimensions.
f. Check for central journal errors due to ovality.
g. Check the crank web for parallelism.
h. Check crank pin for parallelism. Error allowed is 0.0016” per unit
length.
i. Check if propeller shaft has a tapered end in the hub.
j. Check propeller shaft for threads and keyways for burrs and beveling.
k. Check oil seal retainer and sealing for burrs and correct seating.
l. Carry out static and dynamic hardness tests.
14
RECTIFICATION:

a. Score,taper and ovality can be removed by grinding.

b. Slight score and pitting can be removed by grinding or dressing with
carborundum or polishing with emery paper.

RESULT:
Thus the crankshaft is viewed and its dimensions are checked with the
manufacturers’ maintenance manual.

15
 PISTON

16
 2C. VIEWING PROCEDURE - PISTON ASSEMBLY

AIM:-

To carry out view and dimensions check on Piston assembly

TOOLS REQUIRED:-

1. Cleaning Basket
2. Feeler gauge
3. Steel Rule 12”
4. Telescopic Gauge
5. Micrometer
6. Veniercaliper

PROCEDURE:-

Cleaning-check for completeness of the piston assembly and clean it by

dipping in petroleum solvent

Visual Inspection:

a. Examine the piston surface for excessive pitting, cavities or

surface distortion

b. Check the piston rings, lands and piston grooves, piston pin holes
and hole bases for any damages.

17
Dimensional check:-

i. Check side clearance between piston and piston rings- 0.004”,

0.0025’’

ii. Check end clearance on wedge type piston rings.

iii. Check inside diameter of piston pin holes- 0.003’’, 0.004’’.

iv. Clearance between piston slot and cylinder and piston diameter at
top and bottom for taperness.

v. Check outside diameter of piston pin against inside diameter of

hole in piston- 0.0002’’ to 0.0010’’.

vi. Measure fit between piston and plugs and check outside diameter
of plugs -0.0002’’ to 0.0010’’.

vii. Examine interior surface of piston pinhole for corrosion and

pitting.

RESULT:-

The maintenance and inspection of a piston assembly has been

performed according to the Aircraft Maintenance Manual.

18
CONNECTING ROD

19
 2D. VIEWING PROCEDURE- CONNECTING ROD

AIM:-
To perform maintenance and inspection on connecting rod

TOOLS REQUIRED:-
1. Surface plate
2. Micrometer
3. Dial gauge
4. Vernier Caliper
5. Telescopic Gauge
6. Tapered Sleeve
7. Arbor
8. Plug Gauge

PROCEDURE:-

a. Check the connecting rod big end caps for cracks & surface defects by
hot oil & check method
b. Check the rods for notches & abrasions, general condition of big end
bearing and security of dowels.
c. Measure the small end diameter and compare it with external
diameter of gudgeon pin.
d. Check the NIP in the big end bearings and check the internal
dimensions with feeler gauge
e. Check the connecting rod for alignment and twist.
f. Check the CR bolts for elongation and the bolts & nuts for general
conditions of thread.
g. Check for hardness.

20
RECTIFICATION:-

1. During NIP check if 0.004’’ does not go inside, machine the

big end cap and if 0.006’’ goes inside change the cap
2. Any pitting and scoring may be removed by stoning or
polishing, provided it is not too deep.

RESULT:-

The maintenance and inspection of a connecting rod has been performed

according to the Aircraft Maintenance Manual.

21
CAM SHAFT

22
 2E. VIEWING PROCEDURE - CAM SHAFT

AIM:

To view the camhaft and check out its dimensions.

TOOLS REQUIRED:

g. Surface table
h. V-block
i. Dial indicator
j. Vernier caliper
k. Micrometer
l. Magnifying glass

PROCEDURE:

I. Check for cracks by contact current method.

II. Check for corrosion, pitting etc.
III. Check for ovality and taperness using micrometer.
IV. Check external dimensions of journals.
V. Check for central journal errors due to ovality.
VI. Check the lobe for parallelism.
VII. Check the profile and surface of the cam
VIII. Check for run out of the shaft

RECTIFICATION:

23
 (a) Score,taper and ovality can be removed by grinding.
(b) Slight score and pitting can be removed by grinding or dressing
with carborundum or polishing with emery paper.

RESULT:
Thus the camshaft is viewed and its dimensions are checked with the
manufacturers’ maintenance manual.

24
Exp. No. 03 REASSEMBLY OF PISTON ENGINE

AIM:
To re assemble the piston engine after inspection checks.

TOOLS REQUIRED:
a. Special universal socket for spark plug
b. Set spanners 6’-19’
c. Ring spanners 6’-22’
d. Adjustable spanner
e. Pliers and cutters
f. Screwdriver different sizes
g. Hammer
h. Value depression tool
i. Crow foot spanner

PROCEDURE:
a. Insert the tappet and the guides in the crank case.
b. Fix the camshaft after positioning bearing bush.
c. Fix the magneto drive gear.
d. Fix the idle gear and screw the hub bolt.
e. Fix the crankshaft and position the bearing caps.
f. Fix the connecting rod and the bearing caps.
g. Position the top crankcase and then tighten all bolts and nuts.
h. Fix the gearbox with timing gear cover.
i. Fix the magnetos.
j. Fix the position in the connecting rod.
k. Assemble the piston rings on the piston groove and insert the
cylinder over piston and tighten all cylinder large nuts.
l. Fix the cylinder baffle plates.
m. Position the push rod covers and push rods.
25
 n. Fix the rocker shafts.
o. Fix the induction system and carburetor.
p. Fix the air scoop, plug heads with distribution cover.
q. Fix the carburetor controls with universal rods.
r. Fix the starter and other accessories.
s. Fix the spark plug in cylinder head bush and tighten to connect
torques and connect the plug leads.
t. Fix the rocker covers.

RESULT:
Thus the piston engine in reassembled as per maintenance manual
instruction

26
 INTRODUCTION TO JET ENGINE

The major components of a jet engine are similar across the major different
types of engines, although not all engine types have all components. The major
parts include:

 Cold Section:
o Air intake (Inlet) — The standard reference frame for a jet engine
is the aircraft itself. For subsonic aircraft, the air intake to a jet
engine presents no special difficulties, and consists essentially of
an opening which is designed to minimise drag, as with any other
aircraft component. However, the air reaching the compressor of a
normal jet engine must be travelling below the speed of sound,
even for supersonic aircraft, to sustain the flow mechanics of the
compressor and turbine blades. At supersonic flight speeds,
shockwaves form in the intake system and reduce the recovered
pressure at inlet to the compressor. So some supersonic intakes
use devices, such as a cone or ramp, to increase pressure recovery,
by making more efficient use of the shock wave system.
o Compressor or Fan — The compressor is made up of stages. Each
stage consists of vanes which rotate, and stators which remain
stationary. As air is drawn deeper through the compressor, its
heat and pressure increases. Energy is derived from the turbine
(see below), passed along the shaft.
o Bypass ducts much of the thrust of essentially all modern jet
engines comes from air from the front compressor that bypasses
the combustion chamber and gas turbine section that leads
directly to the nozzle or afterburner (where fitted).

27
 Common:
o Shaft — The shaft connects the turbine to the compressor, and
runs most of the length of the engine. There may be as many as
three concentric shafts, rotating at independent speeds, with as
many sets of turbines and compressors. Other services, like a bleed
of cool air, may also run down the shaft.

Diffuser section: - This section is a divergent duct that utilizes

Bernoulli's principle to decrease the velocity of the compressed air to
allow for easier ignition. And, at the same time, continuing to increase
the air pressure before it enters the combustion chamber.

 Hot section:
o Combustor or Can or Flameholders or Combustion Chamber —
This is a chamber where fuel is continuously burned in the
compressed air.
o Turbine — The turbine is a series of bladed discs that act like a
windmill, gaining energy from the hot gases leaving the
combustor. Some of this energy is used to drive the compressor,
and in some turbine engines (i.e. turboprop, turboshaft or turbofan
engines), energy is extracted by additional turbine discs and used
to drive devices such as propellers, bypass fans or helicopter
rotors. One type, a free turbine, is configured such that the turbine
disc driving the compressor rotates independently of the discs that
power the external components. Relatively cool air, bled from the
compressor, may be used to cool the turbine blades and vanes, to
prevent them from melting.
o Afterburner or reheat (chiefly UK) — (mainly military) Produces
extra thrust by burning extra fuel, usually inefficiently, to
significantly raise Nozzle Entry Temperature at the exhaust.
Owing to a larger volume flow (i.e. lower density) at exit from the
28
 afterburner, an increased nozzle flow area is required, to maintain
satisfactory engine matching, when the afterburner is alight.
o Exhaust or Nozzle — Hot gases leaving the engine exhaust to
atmospheric pressure via a nozzle, the objective being to produce a
high velocity jet. In most cases, the nozzle is convergent and of
fixed flow area.
o Supersonic nozzle — If the Nozzle Pressure Ratio (Nozzle Entry
Pressure/Ambient Pressure) is very high, to maximize thrust it
may be worthwhile, despite the additional weight, to fit a
convergent-divergent (de Laval) nozzle. As the name suggests,
initially this type of nozzle is convergent, but beyond the throat
(smallest flow area), the flow area starts to increase to form the
divergent portion. The expansion to atmospheric pressure and
supersonic gas velocity continues downstream of the throat,
whereas in a convergent nozzle the expansion beyond sonic
velocity occurs externally, in the exhaust plume. The former
process is more efficient than the latter.

29
30
Exp.No. 04 DISASSEMBLY OF TURBOJET ENGINE

AIM:

To dismantle the turbojet engine in a proper sequence.

TOOLS REQUIRED:

i. ¾ *1/4 BS or 12-13 set spanner

ii. 10-11 set of ring spanner
iii. 8-9 set of ring spanner
iv. C-spanner
v. Common screw driver
vi. Ball pin spanner
vii. Plier and side cutter

PROCEDURE:

a. Loosen the fine nuts using appropriate spanner and r3emove the inlet
case from the accessory case.
b. Loosen the 10 nuts using no 10-11 set of ring spanner and detach air
casing from compressor case.
c. Remove 15 bolts using no 8-9 set spanner. Detach compressor casing
from diffuser.
d. Loosen retaining nut with C-spanner and remove centrifugal
impeller.
e. Remove front roller bearing and the sleeve.
f. Remove 2 ignition connection and fuel turners from the combustion
chamber outer case.
g. Now take out the turbine along with the shaft from the rear side.
h. Take out the combustion chamber.

31
 i. Loosen the bolts and nuts from the exhaust pipe flange and detach
the exhaust pipe from the combustion chamber.
j. Loosen the clamps of the propelling nozzle and disconnect the nozzle
from the exhaust pipe.
k. Keep all the removed parts separately in the cleaned tray in sequence
so that there is no possibility of mixing with each other.
l. Wherever blanking is required,blank it and place identification slips.

RESULT:

Thus the turbojet engine in dismantled and the components are

studied.

32
Exp.No.05 ASSEMBLY OF TURBO JET ENGINE

AIM:
To assemble a turbojet engine in a proper sequence.

TOOLS REQUIRED:

o ¾ *1/4 BS or 12-13 set spanner

o 10-11 set of ring spanner
o 8-9 set of ring spanner
o C-spanner
o Common screwdriver
o Ball pin spanner
o plier and side cutter

PROCEDURE:

a. Remove all blankings and clean them thoroughly.

Attach air intake case front accessory by tightening all the 5 nuts
Using 12-13 set hammers
b. Attach air intake case rear to the compressor case by tightening all
the nuts using 10-11 set ring spanner
c. Now assemble the compressor in the front and turbine at the rear
of the shaft by inserting the shaft in front of the diffuser case.
d. Enclose the combustion chamber outer case over the flame tube
and tighten all the 15 bolts.
e. Encage 2 ignition and 5 fuel burners connection and tighten the
nuts.
f. Encage the exhaust pipe to combustion chamber outer case flange
and tighten all the bolts and nuts.
33
 g. Attach the propelling nozzle to the rear side exhaust pipe and
together with the clamp.

RESULT:
Thus the turbojet engine is assembled as per the maintenance
manual instructions.

34
 PROPELLER CROSS SECTION

Specimen Blade Set Blade

Location
Leading Edge Trailing Edge Leading Edge Trailing Edge

35
PROPELLER BALANCING

36
Exp.No.6. CHECKING OF PROPELLER PITCH BALANCING

AIM:
To ensure the propeller blade twist is intact.

TOOLS REQUIRED:

Surface table

Degree marked protractor with mounting stand

PROCEDURE:

1. Attach the propeller on the hub stand and place it ont the surface
table.
2. Now position the protractor head near the propeller hub station with
surface table.
3. Now check the angle of the blade near to the hub station.
4. The propeller stations are at a distance from the hub and tip varies
from propeller to propeller.
5. The blade angle is checked from the hub to the tip by moving the
protractor in all directions of the blade stations and also referred the
maintenance manual for the particular airplane adjustment.
6. The propeller track also checked with the help of weight gauge on the
surface table.

RESULT:
Thus the propeller pitch is checked at various stations and compared
with values in maintenance manual.
37
Exp.No.7. FIXED PITCH PROPELLER BALANCING

AIM:

To ensure the propeller is balanced horizontally and vertically.

TOOLS REQUIRED:

Propeller stand with knife-edge support.

Correct size mandrel

PROCEDURE:

1. Insert the mandrel in the propeller shaft hole.

2. Place the mandrel in the knife-edge.
3. Rotate the propeller and to vertical position and ensure it remains in
this position without moving.
4. The vertical balance is corrected by attaching a metal weight to the
lighter side of the hub. The amount of weight is determined by
applying putty at a point normal to the horizontal line. After
balancing, the putty is weighed; a metal plate is cut approximately
equal in weight to the putty. The weight of the metal is adjusted for
the weight of the screw and the solder.
5. The plate is attached to the hub at the location normal to the counter
shrunk screw. Finally varnish is applied.
6. The horizontal balance can be adjusted on a wooden propeller by
adding or removing solder from the balance tip.

RESULT:

Thus the propeller is balanced both vertically and horizontally.

38
 Exp. No.8 AIRPLANE PISTON ENGINE STARTING PROCEDURE

AIM:
To start the given airplane engine according to the maintenance manual
instructions.

PRESTARTING INSPECTION:
The inspection is done to determine the general conditions of
aircraft and engine:

EXTERNAL CHECKS:

a. Head the airplane against wind direction.

b. Remove all protective covers and control locks.
c. Position chocks in front and near main wheel.
d. Position carbon-di-oxide fire extinguisher midway between
the port wing tip and cockpit.
e. Position technicians at port and starboard wing tips to
give clearance before starting.
f. All panels and cowlings should be in place, flaps open.
g. Check fuel for water content and oil for grade.
h. Turn the propeller 5-8 times to remove hrdralisation.
i. Check for correct type pressure and shock strut extension.

39
INTERNAL CHECKS:

1. ·Slide the canopy open.

2. ·Enter the cockpit and take a convenient position.
3. ·Check instrument panel for completion and correction.
4. ·Apply parking brakes to up position.
5. ·Retract flaps to fully up position.
6. ·Take clearance and switch on the battery.
7. ·Open throttle approximately to 1/4 th position.
8. ·Turn the booster pump “ON”
9. ·Move mixture control to fuel rich position until steady flow.
10. ·Return mixture control to idle cut off position.
11. ·Move throttle fully back and switch off booster pump.

STARTING PROCEDURE:

b. Take clearance from marshall.

c. Move throttle forward to 1/4th travel.
d. Set magneto switch on.
e. Press the starter button on to engage.
f. Watch the propeller rotation as soon as the engine picks up.
g. Move the mixture control slowly and smoothly to fuel rich.
h. Release the finger pressure from starter button.
i. Continue to run the engine at 1000-1200 rpm to warm it up.
j. Check oil pressure gauge if minimum oil pressure is not
indicated within 30 seconds, stop the engine and determine the
trouble.
k. If oil pressure cylinder head temperature and oil temperature
readings are satisfactory,continue to run the engine.

40
 l. Run the engine at different ratings not exceeding 1500rpm.
m. Note the rpm, oil temperature and cylinder head temperature.

SHUT DOWN PROCEDURE:

1) Run the engine at idle rpm till CHT decreases continuously.

2) Take clearance from marshal to cut off the engine.
3) Move mixture; throttle to cut off the position.
4) When the engine stops, turn off the booster and ignition pump.
5) Disconnect the battery and check the fuel or oil leakage.
6) Carry out the documentation.

RESULT:
Thus the starting procedure and pre-flight inspections are performed
in aircraft engine and studied.

41
Exp.No.9 NON DESTRUCTIVE TESTING

AIM:

To find the crack or invincible defect in the components and internal

defect using various NDT Techniques

Various NDT Methods:

1. DIE penetrant method

2. Magnetic Particle Inspection
3. Ultra Sonic
4. EDDY Current

DIE PENETRANT METHOD:

Requirments:

1.Die Penetrant

2.Developer

3.Remover

4.Ultra Violet Lamp( UV Lamp)

Procedure:

1. Component to be cleaned with solvent thoroughly before checking

2. Apply Die Penetrant solution (Aerosol Container) on the cleaned surface
evenly and allow 20 min.to get dry
3. Apply developer to make the penetrant to spread to all the surface and
allow 15 min.
4. By using remover over the surface the excess penetrant will be removed
and penetrant which is penetrated will remain in the crack if any
5. With the help of UV Lamp we can identify the presence of crack

This method is useful to identify the presence of defect over the surface only

42
 MAGNETIC PARTICLES INSPECTION (MPI)

Equipment Required:

1. Magnaflux
2. UV Lamp

Theory:
Defects on the surface interrupt the flow of magnetic flux.Magnetic
particles sprayed on the surface are attracted by the gap created by the
crack due the break in the magnetic field.

Procedure:
1. Cleaned component to be kept on the table.
2. With the help of two probes of the MPI Tester touch the end of the
components
3. Magnetize the component by switching on the equipment
4. Sprinkle the special magnetic particles over the surface of the component
5. Demagnetize the component by changing the polarity and allow the free
particles to fall
6. The particles will be inside the crack which can be identified with the
help of UV lamp.

ULTRASONIC FLAW DETECTOR

Equipment Required:

Ultrasonic Flaw Detector

Theory:

The Master timer triggers the signal pulse generator at required intervals. The
signal generator sends a short burnts of high frequency alternate voltage to the
transducer. The transducer generates pulse of ultra sonic waves. When there is
a discontinuity ( crack) in the wave path part of energy is reflected back from
the flaw surface. The reflective pulse causes the receiving transducer element
to vibrate inducing alternating electrical voltage across the transducer which
can be seen in the CRT monitor in wave form of different peaks.

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Procedure:

1. Place the cleaned component on the platform

2. Move the probe over the component after applying couplant to avoid air
gap between probe and component.
3. The CRT monitor will show the deflection in wave form in different
heights.
4. The lowest crest shows the defective location.
5. By calculating the time of return position the crack can be calculated
with the help of the formula

d= vt/2

where d is distance of the crack from the surface

v = velocity of the sound waves of the material
t= transit time ( from the CRT monitor )

EDDY CURRENT METHOD

Requirement:

Eddy Current Tester

Theory:
The changing current in the coil creates an alternating magnetic field. The
varying magnetic field in the crack creates electrical Eddy current in the
material. Discontinuities in the crack will alter the magnitude and
direction of Eddy Current and direction of Eddy Current and this can be
seen in the analog meter.

Procedure:

1. Place the cleaned component on the table

2. Run the probe over the surface of the component
3. The monitor will show a line, if the constant then there is no crack if any
deviation from original then presence of crack is there

Result:

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By the using the above methods the NDT carried out to find the defect in
the given component.

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