Inspection Fundamentals: Mechanic Certification and Safety Regulations

Mechanic Certification and Regulations

• FAA regulations for mechanic certification and operations are under 14 CFR part 65.
• Penalties for cheating on FAA mechanic tests include:
  • Ineligibility for any certificate/rating for 1 year.
  • Suspension/revocation of existing certificates.

Mechanics' English Language Proficiency

• Must be able to read, write, speak, and understand English.
• Exception: Mechanics employed outside the US by a US air carrier.
  • Certificates will state “valid only outside the United States”.

Temporary Certification

• Issued for max 120 days to review application and documents.

Permanent Mechanic Certificate

• Valid indefinitely unless surrendered, suspended, or revoked.
• Reasons for suspension/revoking include document fraud.
• To exercise privileges, must either have recent experience or validated by an FAA administrator within the last 24 months.

Notification of Address Change

• Inform the FAA within 30 days of a permanent mailing address change.

Definition of Maintenance and Preventive Maintenance

• Maintenance: Overhaul, repair, parts replacement, inspection, preservation.
• Preventive Maintenance: Minor operations like changing tires, replenishing fluids.

Inspections and Record Keeping

100-hour Inspections

• Mechanics with a powerplant rating can perform and release powerplant inspections.
• Mechanics with both airframe and powerplant ratings can authorize entire aircraft for return to service.
• Supervising uncertified personnel: The certified mechanic must perform the inspection.

Annual Inspections

• Must use a checklist found in FAR part 43.
• Notify the owner in writing of any defects making the aircraft unairworthy.
• Any appropriately rated mechanic can fix these discrepancies.
• Special Flight Permit required for unapproved departures for maintenance.
• Minor Repairs: Generally do not involve welding/riveting.
• Major Repairs: Involve significant modifications requiring inspection authorization.

Major and Minor Alterations

• Mechanics can approve minor alterations relevant to their certificate ratings.
• Major alterations and repairs require approval from a mechanic with inspection authorization and entry into FAA form 337.

FAA Form 337

• Mandatory for documenting major repairs/alterations; two copies needed.
• Mechanic performing/supervising the work prepares the form, certifying compliance with 14 CFR part 43.

Maintenance Record Retention

• Must be kept for at least 1 year or until work is repeated/superseded.
• Lost records: Reconstruct total time in service researching past repair facilities/mechanics.

Inspection Entries

• Must include: work description/references, completion date, name of the person performing work, signature, certificate number, and type.

Airworthiness Certificates

• Covered in part 21, subpart H of Federal Aviation Regulations and transferred with the aircraft if sold.

Type Certificate Data Sheets and Aircraft Specifications

• Provide info on required equipment, suitable propellers, necessary placards, datum location, control surface movements.
• Code Example (e.g., 2 PCSM): Two-place, closed cockpit, seaplane, monoplane.

Supplemental Type Certificates (STC)

• Approved deviations from the original design.
• Approval needed post-compliance to ensure no negative interactions.

Technical Standard Orders (TSOs)

• Set performance/environmental standards for equipment.
• TSOs themselves do not authorize installation; separate approval needed for specific aircraft.

Airworthiness Directives (ADs)

• Mandatory to correct unsafe conditions; compliance timeframe and actions specified.
• Actions: Inspections, parts replacement, modifications, operational changes.
• AD Compliance: Checked during inspections required under parts 91, 125, 135; records kept indefinitely.

Non-Destructive Testing (NDT) Methods

Magnetic Particle Inspection

• Detects surface/subsurface flaws in magnetic materials.
• Uses dry/wet ferromagnetic particles to visualize defects.
• Demagnetization: Use decreasing alternating current.

Dye Penetrant Inspection

• Detects surface defects in non-porous materials like aluminum.
• Steps: Clean surface, apply penetrant, remove excess, apply developer, inspect.

Eddy Current Inspection

• Detects intergranular corrosion in non-ferrous metals using induced currents.

Radiographic Inspection

• Uses X-rays/Gamma rays to detect deep-seated defects, little/no disassembly required.
• Suitable for internal structural inspections (e.g., wings, cast aluminum fittings).

Metallic Ring Test

• Detects defects by tapping and listening for a metallic ring.

Key Takeaways

• Mechanic certification and maintenance standards critical for SAFETY and COMPLIANCE.
• Extensive DOCUMENTATION ensures traceability and accountability.
• Periodic training & vigilance essential for maintaining certification and operational privileges.

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