aero-agent-roles 1.0.0

package/roles/ndt-engineer/templates/ndt-plan-template.md

@@ -0,0 +1,109 @@
+# Nondestructive Test Plan and Method Selection Report
+
+**Item:** Main Gearbox Housing (investment casting)  (PN 7450-103)
+**Material:** A356 aluminum alloy casting (non-ferromagnetic, 30 pct IACS)  **Route:** investment cast + T6
+**Drawing:** DWG 7450-103 rev C
+**Certification basis:** AS9100D special-process control; NAS 410 personnel qualification practice
+**Status:** draft-for-review
+
+Scope: Critical cast aluminum gearbox housing; the casting is fully machined after NDT and holds oil under pressure in service.
+
+## 1. Candidate defect population and method selection
+
+Method selection follows the bound ndt-method-selection decision logic: defect class (surface / near-surface / internal) x material class (non-ferromagnetic) defines the applicable set, and sensitivity rank (UT 5, RT/ET 4, MT/PT 3) picks the method (cost is reporting only).
+
+### 1.1  Fatigue crack at oil-feed boss
+
+- Zone / note: surface-breaking crack zone on the machined boss face (non-ferromagnetic aluminum)
+- Defect class: surface  ·  material class: non-ferromagnetic
+- Applicable methods: eddy current testing (ET) (sensitivity 4), liquid penetrant testing (PT) (sensitivity 3)
+- **Selected method: eddy current testing (ET)** — surface defect in non-ferromagnetic material: ET is the highest-sensitivity applicable method.
+- Alternates: liquid penetrant testing (PT)
+
+### 1.2  Subsurface gas porosity under machined skin
+
+- Zone / note: near-surface gas porosity band beneath the machined skin
+- Defect class: near-surface  ·  material class: non-ferromagnetic
+- Applicable methods: eddy current testing (ET) (sensitivity 4), ultrasonic testing (UT) (sensitivity 5)
+- **Selected method: ultrasonic testing (UT)** — near-surface defect in non-ferromagnetic material: UT is the highest-sensitivity applicable method.
+- Alternates: eddy current testing (ET)
+
+### 1.3  Internal shrinkage porosity in lug section
+
+- Zone / note: internal shrinkage/gas porosity population in the thick lug section
+- Defect class: internal  ·  material class: non-ferromagnetic
+- Applicable methods: radiography (RT) (sensitivity 4), ultrasonic testing (UT) (sensitivity 5)
+- **Selected method: ultrasonic testing (UT)** — internal defect in non-ferromagnetic material: UT is the highest-sensitivity applicable method.
+- Alternates: radiography (RT)
+
+## 2. Inspection parameters per selected method
+
+_Parameter rows below are computed by the role core mirroring the bound method leaf logic. The qualified procedure and the engineering specification govern the actual inspection settings._
+
+### 2.1 Eddy current (ET) — surface zone
+- Flaw depth: 0.001 m; conductivity 30 pct IACS (1.74e+07 S/m)
+- Test frequency (penetration factor 0.5): **58231 Hz**; standard depth of penetration **0.0005 m**
+- Current density at the flaw depth: 0.135 of surface; phase lag 114.59 deg
+
+### 2.2 Eddy current (ET) — near-surface zone
+- Subsurface flaw depth 0.001 m: frequency **3639 Hz**, standard depth of penetration 0.002 m keeps the flaw at half a delta (density ratio 0.607, phase lag 28.65 deg)
+
+### 2.3 Liquid penetrant (PT) — surface-breaking crack zone
+- Penetrant: gamma 0.032 N/m, contact angle 5 deg, viscosity 0.008 Pa.s; crack opening 4e-06 m -> effective capillary radius 2e-06 m
+- Capillary pressure across the meniscus: **3.19e+04 Pa**
+- Washburn model: penetration depth 0.03458 m at the 300 s reference dwell; computed time to fill the 0.001 m-deep reference crack 0.251 s (dwell scales with depth squared and inversely with crack radius)
+- Indication sizing: bleed-out width 1.6e-05 m for the 4e-06 m opening (ratio 4.0); developer 0.075 kg at 0.15 kg/m2 over 0.50 m2; fluorescent contrast vs background 0.938
+- Dwell: procedure-qualified penetrant dwell governs; the model numbers above are sizing inputs, not settings.
+
+### 2.4 Radiography (RT) — internal volumetric zone
+- Setup: focal spot 3.0 mm, SOD 500 mm, ODD 30 mm -> geometric unsharpness **0.18 mm** (limit 0.25 mm)
+- Exposure (inverse-square): **1.39 min** at the working distance
+- IQI sensitivity: 2.00 pct (0.6 mm visible on 30 mm section; limit 2.0 pct)
+- Film density 2.50 in band 2.0-4.0 (acceptable); technique verdict: **acceptable**
+- Expected discontinuity class from image geometry: porosity (acceptance criteria per class)
+
+### 2.5 Computed tomography (CT) — supplemental volumetric sizing
+- Magnification 2.00, voxel size 0.0001 m; required flaw 0.0005 m
+- Resolution: PASS: smallest detectable feature 3.000e-04 m (3 voxels) is at or below the required 5.000e-04 m flaw size
+- Scan plan: 1609 projections at 350 kV (161 s), material aluminum thickness 50 mm
+- Porosity ROI: 0.8 pct void fraction, equivalent spherical void diameter 0.00496 m; CT number +400 HU -> light-alloy
+
+### 2.6 Magnetic particle (MT) — ferromagnetic parts
+- Not applicable to this non-ferromagnetic part; retained in the method library for ferromagnetic parts (forgings, steel castings).
+
+### 2.7 Leak test (LT) — sealed assembly
+- Method recommendation: **pressure-decay** — only one side accessible and the part holds pressure, so a decay test on the sealed internal volume fits
+- Pressure decay: 5 L at dP 0.02 bar over 600 s -> leak rate **0.1645 scc/s**; allowable 0.2 scc/s -> disposition **accept** (margin 0.85 dB)
+- Gauge adequacy: 0.0005 bar resolution needs >= 12.3 s to catch the allowable leak; test time 600 s is adequate
+
+## 3. NDT personnel qualification
+
+- Operator level: Level II (supervisor Level III)
+- Certification status as of 2026-09-05: **current** (recert due 2027-09-05; near-vision due 2027-03-05)
+- Supervision pairing: valid (Level I operators work under Level II/III)
+- Upgrade evaluation (toward Level III): eligible when hours, months and examination are met
+- Per-method certification check (interpretation of results requires the level shown):
+  - PT: Level II to interpret, Level I to perform — operator meets
+  - ET: Level II to interpret, Level I to perform — operator meets
+  - UT: Level II to interpret, Level I to perform — operator meets
+  - RT: Level II to interpret, Level I to perform — operator meets
+  - CT: Level II to interpret, Level II to perform — operator meets
+  - LT: Level II to interpret, Level II to perform — operator meets
+
+## 4. Acceptance and disposition framing
+
+All dispositions in this plan are INPUTS for the responsible engineering authority; the customer acceptance document and the qualified procedure govern.
+
+- **ET:** signal amplitude and phase vs the calibrated reference standard gate sizing; indications are evaluated against the acceptance document for the zone (crack-like vs volumetric responses)
+- **PT:** rounded indications (pores) and linear indications (cracks, laps) are sized from the bleed-out image and evaluated against their class limits; excessive background is a process failure, not an indication
+- **RT:** the discontinuity class (porosity / crack / inclusion / slag) gates the applicable acceptance criteria; the technique verdict (unsharpness, IQI sensitivity, film density) must be acceptable before any disposition is made
+- **CT:** segmented void fraction and equivalent void diameter are disposition inputs against the casting acceptance standard; resolution must first pass the required-flaw check
+- **LT:** measured leak rate is accepted when at or below the maximum allowable, rejected when above 1.25x the allowable, reviewed in between (margin band)
+
+## 5. Open items for the responsible authority
+
+- Confirm the acceptance limits and the qualified procedure revisions named in the drawing and the program plan.
+- Confirm operator certification records and intervals match the employer's written practice.
+
+---
+*Generated by Aero Agent Roles ndt-engineer core (2026-09-05). DRAFT for human NDT engineering review. Not an approval document; carries no acceptance or certification authority.*

package/roles/ndt-engineer/tests/test_ndt_cli_bundle.py

@@ -0,0 +1,183 @@
+#!/usr/bin/env python3
+"""Test the evidence bundle + skill-dispatch protocol for ndt-engineer
+(PROTOCOL.md v1).
+
+Verifies:
+- build --bundle emits evidence/{model,gates,provenance}.json
+- bundle JSON parses; model contains the computed method-selection rows
+  and parameter cards; gates all_pass; exit code 0
+- skill dispatch cross-checks core numbers against the bound ndt leaf
+  logic (agreeing within tolerance) when AeroSkills is present
+- standalone (AEROSKILLS_DEV=/nonexistent) emits the bundle honestly
+  with cross_checked=false
+- build --leak-limit-sccs re-runs the disposition
+- check --file passes the gate vocabulary
+- a malformed profile fails loudly with exit 1
+"""
+import json
+import os
+import shutil
+import subprocess
+import sys
+import tempfile
+import unittest
+
+ROLE_DIR = os.path.dirname(os.path.dirname(os.path.abspath(__file__)))
+CLI = os.path.join(ROLE_DIR, "cli.py")
+REPO_ROOT = os.path.dirname(os.path.dirname(os.path.dirname(
+    os.path.dirname(os.path.abspath(__file__)))))
+PROFILE = os.path.join(REPO_ROOT, "profiles", "example-airframer.json")
+EXPECTED_CUSTOMER = "Example Airframers Ltd"
+
+AEROSKILLS = os.environ.get("AEROSKILLS_DEV",
+                            os.path.expanduser("~/AeroSkills"))
+HAS_SKILLS = os.path.isdir(os.path.join(AEROSKILLS, "skills"))
+
+# Functions the CLI should dispatch against the bound leaf logic.
+EXPECTED_DISPATCH_FNS = [
+    "select_frequency_for_flaw",      # eddy-current-inspection
+    "capillary_pressure",             # liquid-penetrant-inspection
+    "exposure_time",                  # radiographic-inspection
+    "projection_count",               # computed-tomography
+    "pressure_decay_rate",            # leak-testing
+]
+
+
+def run_build(outdir, extra_args=None, env_extra=None):
+    env = dict(os.environ)
+    if env_extra:
+        env.update(env_extra)
+    args = [sys.executable, CLI, "build", "--out",
+            os.path.join(outdir, "plan.md"), "--bundle"]
+    if extra_args:
+        args.extend(extra_args)
+    return subprocess.run(args, capture_output=True, text=True, env=env)
+
+
+class TestNdtCliBundle(unittest.TestCase):
+
+    def setUp(self):
+        self.tmp = tempfile.mkdtemp()
+
+    def tearDown(self):
+        shutil.rmtree(self.tmp, ignore_errors=True)
+
+    def _model(self):
+        return json.load(open(os.path.join(self.tmp, "evidence",
+                                           "model.json")))
+
+    def _gates(self):
+        return json.load(open(os.path.join(self.tmp, "evidence",
+                                           "gates.json")))
+
+    def _prov(self):
+        return json.load(open(os.path.join(self.tmp, "evidence",
+                                           "provenance.json")))
+
+    def test_bundle_emits_three_files_exit_zero(self):
+        r = run_build(self.tmp)
+        self.assertEqual(r.returncode, 0, r.stderr[-500:])
+        for f in ("model.json", "gates.json", "provenance.json"):
+            self.assertTrue(os.path.exists(os.path.join(self.tmp, "evidence",
+                                                        f)))
+
+    def test_model_content_and_gates(self):
+        r = run_build(self.tmp)
+        self.assertEqual(r.returncode, 0)
+        m = self._model()
+        self.assertEqual(m["role"], "ndt-engineer")
+        self.assertEqual(m["status"], "draft-for-review")
+        self.assertEqual(
+            m["document_type"],
+            "Nondestructive Test Plan and Method Selection Report")
+        self.assertEqual([x["top_method"] for x in m["defect_population"]],
+                         ["ET", "UT", "UT"])
+        self.assertIn("eddy-current-surface", m["parameter_cards"])
+        self.assertIn("liquid-penetrant", m["parameter_cards"])
+        self.assertIn("radiography", m["parameter_cards"])
+        self.assertIn("computed-tomography", m["parameter_cards"])
+        self.assertIn("leak-test", m["parameter_cards"])
+        g = self._gates()
+        self.assertTrue(g["all_pass"])
+        self.assertEqual(g["exit_code"], 0)
+
+    def test_dispatch_crosscheck_when_skills_present(self):
+        r = run_build(self.tmp)
+        self.assertEqual(r.returncode, 0)
+        prov = self._prov()
+        fns = [row["function"] for row in prov["skills"]]
+        if HAS_SKILLS:
+            for fn in EXPECTED_DISPATCH_FNS:
+                self.assertIn(fn, fns, "expected dispatch fn missing: " + fn)
+            self.assertTrue(prov["cross_checked"])
+            self.assertTrue(all(row["agrees"] for row in prov["skills"]),
+                            [row for row in prov["skills"]
+                             if not row["agrees"]])
+            for row in prov["skills"]:
+                self.assertLessEqual(row["delta"], 1e-6)
+        else:
+            self.assertEqual(prov["skills"], [])
+            self.assertFalse(prov["cross_checked"])
+
+    def test_standalone_honest_bundle(self):
+        r = run_build(self.tmp, env_extra={"AEROSKILLS_DEV": "/nonexistent"})
+        self.assertEqual(r.returncode, 0)
+        prov = self._prov()
+        self.assertEqual(prov["skills"], [])
+        self.assertFalse(prov["cross_checked"])
+        # deliverable is still complete and gate-passing standalone
+        m = self._model()
+        self.assertTrue(m["defect_population"])
+        g = self._gates()
+        self.assertTrue(g["all_pass"])
+
+    def test_leak_limit_override_changes_disposition(self):
+        r = run_build(self.tmp, ["--leak-limit-sccs", "0.1"])
+        self.assertEqual(r.returncode, 0)
+        m = self._model()
+        self.assertEqual(m["parameter_cards"]["leak-test"]["verdict"],
+                         "reject")
+        # plan gates remain green; the disposition data is honest
+        self.assertTrue(self._gates()["all_pass"])
+
+    def test_profile_header_and_model(self):
+        if not os.path.exists(PROFILE):
+            self.skipTest("profiles/example-airframer.json not present")
+        r = run_build(self.tmp, ["--profile", PROFILE])
+        self.assertEqual(r.returncode, 0, r.stderr[-500:])
+        md = open(os.path.join(self.tmp, "plan.md")).read()
+        self.assertTrue(md.startswith("## Program context"))
+        self.assertIn("Customer: " + EXPECTED_CUSTOMER, md)
+        m = self._model()
+        self.assertEqual(m["profile"]["customer"], EXPECTED_CUSTOMER)
+        self.assertEqual(m["status"], "draft-for-review")
+        # gate-check still passes on the profiled markdown
+        c = subprocess.run([sys.executable, CLI, "check", "--file",
+                            os.path.join(self.tmp, "plan.md")],
+                           capture_output=True, text=True)
+        self.assertEqual(c.returncode, 0, c.stdout)
+        self.assertIn("RESULT: PASS", c.stdout)
+
+    def test_malformed_profile_fails_loudly(self):
+        bad = os.path.join(self.tmp, "bad-profile.json")
+        with open(bad, "w") as f:
+            json.dump({"program": "no customer here"}, f)
+        r = run_build(self.tmp, ["--profile", bad])
+        self.assertEqual(r.returncode, 1)
+        self.assertIn("error: bad profile", r.stdout)
+
+    def test_check_command_gate_vocabulary(self):
+        r = run_build(self.tmp)
+        self.assertEqual(r.returncode, 0)
+        c = subprocess.run([sys.executable, CLI, "check", "--file",
+                            os.path.join(self.tmp, "plan.md")],
+                           capture_output=True, text=True)
+        self.assertEqual(c.returncode, 0)
+        self.assertIn("RESULT: PASS", c.stdout)
+        for name in ("has_title", "has_selection", "has_personnel",
+                     "has_not_approval"):
+            self.assertIn(name, c.stdout)
+
+
+if __name__ == "__main__":
+    unittest.main()