Aircraft integrity: Inspectors ensure force stays battle ready

Published May 19, 2026
By Joseph Mather
78th Air Base Wing Public Affairs

ROBINS AIR FORCE BASE, Ga. --

Photo shows a man using instruments to perform a test on the side of an aircraft. — ROBINS AIR FORCE BASE, Ga. – Ben Wheeler, 558th Aircraft Maintenance Squadron nondestructive inspector, performs an ultrasonic straight beam inspection delamination test to the outboard side of an F-15 aircraft stabilizer at Robins Air Force Base, Georgia, Dec. 10, 2025. NDI inspectors at Robins AFB tested the F-15 to ensure the integrity of the aircraft as part of its programmed/scheduled depot maintenance. (U.S. Air Force photo by Joseph Mather)

Before an Air Force aircraft takes to the skies, a dedicated team of inspectors at the Warner Robins Air Logistics Complex at Robins Air Force Base, Georgia, meticulously examines every inch of the airframe, searching for hidden flaws that could compromise safety and mission readiness.

These aren't your everyday visual checks. The Non-Destructive Inspection team employs a sophisticated arsenal of high-tech methods to detect even the most minute imperfections.

This critical work directly supports the Air Force Structural Integrity Program ensuring aircraft remain structurally sound and warfighters have confidence in the aircraft’s ability to perform the mission.

"The inspection process helps support the AFSIP, designed for maintaining structural integrity of the aircraft and instill confidence in the warfighter of our aircraft’s airworthiness," said Amy Day, a 558th Aircraft Maintenance Squadron Level II non-destructive inspector.

Photo shows man using a small machine on a piece of metal. — ROBINS AIR FORCE BASE, Ga. – Dakota Holt, 558th Aircraft Maintenance Squadron nondestructive inspector, performs an eddy current array scan on a horizontal box beam panel for a C-5 aircraft horizontal stabilizer at Robins Air Force Base, Georgia, Dec. 10, 2025. The eddy current radius scan array checked for cracks and allowed NDI technicians to test the structural integrity of the aircraft skin. (U.S. Air Force photo by Joseph Mather)

To find these hidden flaws without harming the aircraft itself, inspectors employ a range of sophisticated techniques that allow for thorough examination with minimal disassembly.

"We use a variety of NDI methods to find flaws without ever damaging the aircraft parts. We send ultrasound waves through the metal to find hidden cracks and use a fluorescent dye that makes tiny defects glow,” said Ben Wheeler, a 558th AMXS nondestructive inspector. “The best part of NDI is that we see the results immediately, and the airframe structure remains intact.”

The data collected from these inspections is invaluable, helping to determine the overall structural health of the aircraft and allowing engineers to devise appropriate solutions, known as a Total Technical Resolution.

Photo shows man looking at computer screen — ROBINS AIR FORCE BASE, Ga. – James Brownlee, 558th Aircraft Maintenance Squadron nondestructive inspector, reviews and makes annotations on an image while looking for water entrapment from a digital photo of a F-15 aircraft rudder at Robins Air Force Base, Georgia, Dec. 10, 2025. The water entrapment test was conducted to identify any fluid inside the aircraft part. (U.S. Air Force photo by Joseph Mather)

The data collected includes cracks, stress, fatigue, gouges, corrosion, manufacturing defects, water entrapment, foam adhesive separation and foreign objects. This data is utilized by structural engineering and various skills to determine TTR.

The process begins with rigorous training where inspectors undergo thousands of hours of training and face multiple written and practical exams to become certified. Once certified, they must take a yearly practical test to remain proficient.

While technicians prove their proficiency through these tests, the future of the mission is advancing toward AI augmentation and integrated robotics.

Broderick Henry, a 402nd Aircraft Maintenance Support Squadron Production Support Flight supervisor, said the next evolution involves intelligent systems and collaborative robots.

“These robotics will work in tandem with both human technicians and other robotic platforms to create a more efficient, proactive and safer inspection environment," he said.

Photo shows woman using a machine to perform measurements on a large piece of metal. — Aircraft integrity: Inspectors ensure force stays battle ready

ROBINS AIR FORCE BASE, Ga. – Madalina Maynard, 558th Aircraft Maintenance Squadron nondestructive inspector work leader, performs a delamination test with ultrasonic straight beam inspection to an F-15 aircraft stabilizer at Robins Air Force Base, Georgia, Dec. 10, 2025. The nondestructive inspection determined the aircraft stabilizer honeycomb core had not separated from the skin, a process known as delamination. (U.S. Air Force photo by Joseph Mather)

Photo shows two men working around a table while reviewing papers. — Aircraft integrity: Inspectors ensure force stays battle ready

ROBINS AIR FORCE BASE, Ga. – Brandon Alford, left, 571st Commodities Maintenance Squadron nondestructive inspector, and Pedro Loera, NDI engineer, discuss NDI procedures in a formal Level 2 training class at Robins Air Force Base, Georgia, Dec. 15, 2025. The nondestructive inspectors attended a 32-hour training course for Level 2, which gives concepts of inspection methods with practical applications to NDI. (U.S. Air Force photo by Joseph Mather)

Photo shows man using machine to perform measurements on pieces of metal. — Aircraft integrity: Inspectors ensure force stays battle ready

ROBINS AIR FORCE BASE, Ga. –Robert Thrasher, 558th Aircraft Maintenance Squadron nondestructive inspector, performs an eddy current scan open fastener hole scan on a horizontal box beam panel for a C-5 aircraft horizontal stabilizer at Robins Air Force Base, Georgia, Dec. 10, 2025. The scan checked for cracks in the screw holes to a panel that fits into a C-5 aircraft horizontal stabilizer. (U.S. Air Force photo by Joseph Mather)