A fuel tank's integrity is essential to an aircraft's safety. Failure of a fuel tank is one of the severe issues which may cause fuel leakage, fire, or structural failure.
Fuel leakages are some of the biggest dangers associated with airplanes and the people on board them. They can culminate in problems such as fuel loss, decreased efficiency, or complete motor breakdown. Fuel tank leakage can sometimes lead to fires that endanger the whole aircraft.
This blog post will discuss how to detect and prevent leakage and the various measures that one can take to ensure that fuel tanks do not develop such leakage in the future.
Detection Methods
Visual Inspection
Visual inspection is the easiest and most fundamental method of identifying fuel tank leaks.
In a visual inspection, technicians examine the fuel tank for signs of damage, such as cracking, pinholes, or corrosion.
This can be done during the system's service or after a break and leakage has been suspected.
Dye Penetrant Testing
Dye penetrant testing is one form of nondestructive testing that can be adopted to detect discontinuities in a material that is on the surface-breaking crack.
An ink is initially placed on the surface of the fuel tank, and then a developer is applied to highlight any damages.
This is when one paints the area with the developer, and you notice that if there is a crack or discontinuity, the dye will penetrate it.
Magnetic Particle Testing
The other Nondestructive Testing (NDT) technique is magnetic particle testing, which can detect surface and subsurface defects in ferromagnetic material.
A magnetic field is first applied to the fuel tank, and then the iron filling is spread over that fuel tank area.
Flaws in this material will disorganize the magnetic field, gathering the iron fillings at the defect.
Ultrasonic Testing
Ultrasonic testing is a nondestructive testing method that uses high-frequency sound waves to detect defects within materials.
The sound waves are aimed at the fuel tank; if a defect exists, they will be reflected.
The defect may also be detected from the reflected sound waves, and its size and position may be estimated.
Infrared Thermography
Infrared thermography is an NDT testing technique that uses an infrared camera to determine the variation in the temperature of the material.
This method helps identify regions likely to have fuel leakage because fuel is usually colder than the surrounding surface material.
If there is a leak, fuel will cool the surrounding area around where the leak is coming from creating a temperature contrast that will make the fuel appear when the camera is being used.
Fuel Tank Leak Detection System
However, fuel tank leak detection systems unique to conventional techniques can also be used.
Such systems can employ various technologies, including sensors, pressure measurement, and gas detection, and provide technicians with real-time alerts of probable leakage.
Preventive Strategies
Strategy #1: Material Selection And Quality Control
High-quality materials: To ensure that the fuel tank lasts a long time, it is essential to choose materials that are immune to corrosion, fatigue, and impact.
Strict quality control: Strict standards and quality control measures must be adhered to to ensure suitable materials are used to construct the chassis.
Strategy #2: Proper Manufacturing Techniques
Acorn welding: As an aviation welding technician, Acorn welding uses a specialized technique to create strong and durable joints in fuel tanks.
Other techniques: Other manufacturing processes that can be used in the production of fuel tanks involve riveting and bonding. However, this practice must be done appropriately to offer the much-needed strength to the equipment.
Strategy #3: Regular Maintenance And Inspections
Scheduled inspections: It is crucial to perform scheduled checks of fuel tanks and determine whether any problematic signs may evolve into leaks.
Visual inspections: They also include forms of eyeballing, where one can see signs of damage such as cracks, pinholes, or even corrosion.
Non-destructive testing: Localized surface crack indications can be detected and identified using other methods, including dye penetrant testing, magnetic particle testing, and ultrasonic testing for internal defects.
Strategy #4: Corrosion Prevention Measures
Protective coatings: Anticorrosive paints on the interior and exterior of fuel tanks are also suitable for protecting them.
Moisture control: It thus becomes pertinent to stress that fuel tanks should not be exposed to moisture since this leads to rust.
Regular cleaning: This also means that fuel tanks must be cleaned, as accumulations on the interior of the tank can lead to corrosion.
Strategy #5: Fuel Tank Sealing And Coating
Sealing materials: High-quality sealing materials can minimize leakage at joints and connection areas.
Protective coatings: Varnishing or painting the inner and outer surfaces of the fuel tanks can help prevent corrosion and leakage.
Who We Are?
Acorn Welding is a specialized independent company offering welding services focusing on the aerospace sector. Our company has been in the business for a long time and has deployed the best workforce, so we provide high quality and reliability in all your projects. We specialize in acorn welding and other modern welding methods, so we manage to fulfill the high demands of the aviation industry to provide safe and durable aircraft.
Are you looking for professional welding services for your airplane? If you have any questions or want to learn more about Acorn Welding, please contact us now. Our company is committed to ensuring every client gets the services they want.
