Composite Blades Inspection

Report
Technical Issues Review
Presented By:
Michael Mayhill
The information in this presentation is not intended to supersede,
replace, or be used in lieu of approved published documentation.
1
Technical Issues Review
 Composite Blades
 Aluminum Blades
 Hubs
 Seals
 Spinner
 De-ice
 Miscellaneous
 Status Updates
2
Your Input Appreciated
 Some of our best fixes have been suggested by
the field
 You see these products in normal and extreme
conditions every day –
– What do you see that is working?
– What do you see that is not working?
– Do you have suggestions to make something
better?
3
Composite Blades
ASC II
 As of September 24th there
were 4087 of the composite
N7605( ) blades
manufactured
 These blades are becoming
more and more popular with
your customers
 We are working to develop
new applications
 More are manufactured
every day
4
Composite Blades
ASC II
 HC-SL-61-294:
 Field Inspection and Minor
Repair Criteria for N7605( )
blades [May 07/09]
 Previously in Manual 135F only
5
Composite Blades
ASC II
 HC-SL-61-294:
 Defines permitted field
repairs for A&P mechanics
 Damage beyond minor repair
limitations must go to a
certified propeller service
facility
6
Composite Blades
Inspection
 HC-ASB-61-306 rev. 2:
 N7605B blade ‘crack’
indication in boot area
– Evaluation found
‘soft spot’ at the
‘crack’ location
– Resin did not properly
cure during early
production process
7
Composite Blades
Inspection
 HC-ASB-61-306 rev. 2:
 Inspections of N7605( )
– Effectivity is s/n specific
to early production
– 387 blades affected
8
Composite Blades
Inspection
 HC-ASB-61-306 rev. 2:
 Visual Inspection:
– Recurring visual
inspection every 100
hrs/annual
• Reporting required
• A&P can accomplish
– Warranty coverage for
visual
9
Composite Blades
Inspection
 HC-ASB-61-306 rev. 2: Inspection of N7605( )
– Terminating Action UT Inspection at or before overhaul
• Reporting required
• Accomplished by Level II or III
• 52 inspections completed, 6 blades replaced
10
Composite Blades
Inspection
11
Composite Blades
Inspection
12
Composite Blades
Inspection
 HC-ASB-61-306 rev. 2: Inspection of N7605( )
– UT equipment available for loan
– Warranty coverage for UT at overhaul
13
Composite Blades
Staking Pins
 Staking pins found
sheared during standard
engineering evaluation of
high-time N7605( )blade
– No performance
issues noted
– Design improvement
with larger staking pins
14
Composite Blades
Staking Pins
 HC-SB-61-319: Staking
Pins [pending]
– Affects N7605( ) and
N7893( ) blades by s/n
• 3658 blades
– Terminating Action at
overhaul
• Index to new location
• Insert new, larger pins
– Does not affect life of
product
15
Composite Blades
Staking Pins
Was B-5996-628 Ø=0.125”
Now B-5996-640 Ø=0.1875”
(Production)
16
Aluminum Blades
Production Rolling Issue
 HC-SB-61-318 rev. 1: Blade Inspection [Jun 15/10]
 Internal production process issue
– M, P, and R shank blades from Jul 09 – Jan 10
– Cost analysis led to engineering review
• Reduced minimums approved
• Manual update pending
17
Aluminum Blades
Production Rolling Issue
 HC-SB-61-318 rev. 1: Blade
Inspection [Jun 15/10]
– M, P, and R shank blades by s/n
• K85813 – K97065
– Optical Comparator Inspection
– Factory only rework
18
Aluminum Blades
Production Rolling Issue
 HC-SB-61-318 rev. 1: Blade
Inspection [Jun 15/10]
– Reworked and non-reworked
may be mixed in a propeller
assembly if balance can be
achieved
– No loss of clamping force due
to clamp design
19
Aluminum Blades
NaCl Contamination
 HC-ASB-61-322: Blade Replacement [pending]
– Fissure indication in the blade bore discovered at
overhaul inspection
– Originated from Sodium Chloride contamination within
the ingot
– Potentially all blades forged from that ingot could be
contaminated
20
Aluminum Blades
NaCl Contamination
 HC-ASB-61-322: Blade Replacement [pending]
– Affects Y-shank aluminum blades by serial number
• 452 blades affected
• 82 left Hartzell as blade only shipment
We are Considering:
– Replacement within 250 hours/ 24 calendar months,
whichever occurs first
• Any inventory/stock replacement within 24 calendar months
21
Aluminum Blades
NaCl Contamination
 HC-ASB-61-322: Blade Replacement [pending]
– Affected blades MUST be retired and destroyed
– Airworthiness Directive is possible
– Warranty:
• Replacement Blades free of charge until Nov 30, 2016
• Some additional coverage for props maintained IAW SL61Y
22
Hubs
Lubrication Fittings
 HC-SL-61-187 rev. 3: 45˚ Lubrication
Fitting [Nov 13/09]
– Originally issued Oct 15/98
– Revision 3 removed torque
• “Tighten until snug”
 Any issues with the zerk fittings?
23
Hubs
Modification
 HC-SI-61-206: Hub Modification – Bore Bushing
– Dimensional specifications for machining of bore and
bushing on lightweight turbine propellers
– Available on request
– Revision needed for additional part numbers
 Pending Changes related to Sample Program review
24
Hubs
1900D Inspection
 HC-ASB-61-316 rev. 1: Hub
Inspection [Jun 26/09]
– Two 1900D hubs found
fractured near dowel holes
and oversize inserts on
mounting flange
– Found at overhaul
inspection
25
Hubs
1900D Inspection
 HC-ASB-61-316 rev. 1: Hub
Inspection [Jun 26/09]
– ~800 hubs affected
– Initial visual inspection
based on TSO
– As required following visual:
• ECI
• Stamp hub “K”
• REPORTING
REQUIRED
26
Hubs
1900D Inspection
 HC-ASB-61-316 rev. 1: Hub
Inspection [Jun 26/09]
– 273 inspected
• No indications
– Recurring ECI every 1000 hrs
• REPORTING REQUIRED
– ECI required at each
overhaul
• REPORTING REQUIRED
27
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore
Bushing [pending]
– Compact -1 propeller on a
Beechcraft Bonanza
stopped actuating in flight
– Investigation found failed
bore bushing with oil
behind the piston
– Hydraulic lock
28
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore
Bushing [pending]
– Failure to seal due to:
• No bushing
– Scored bore / damaged o-ring
• Bushing installed with adhesive
– Failed adhesive
– Bushing Slippage
29
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore
Bushing [pending]
– Propeller operates, doesn’t
actuate
• Defaults to low pitch, high RPM
• Operates as fixed pitch propeller
30
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore
Bushing [pending]
– Bonanza pilot set up for
POH ‘Best Glide’
• Not compatible with low
pitch, high RPM setting
for Bonanza
– FAA SAIB-CE-10-21
issued to notify pilots
31
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore Bushing [pending]
– Compliance required for any Bonanza or Debonair w/ (
)HC-(C,G,L)(2,3,4)Y(F,K,R)-1( )
• Propellers NOT maintained IAW SL61Y:
200 hrs, 12 calendar months, or next major
disassembly, whichever occurs first
• Propellers maintained IAW SL61Y:
next major disassembly or SL61Y overhaul limit,
whichever occurs first
32
Hubs
Bonanza/Debonair Bushing
 HC-SB-61-315: Hub Bore
Bushing [pending]
– Serial number prefix
identifies affected hubs
– Perform applicable pitch
change rod bore repair
procedure IAW Manual 202A
33
Hubs
Production Bushing (-1)
 HC-SL-61-305 [pending]
– Production change for all
standard -1 hubs
• Does not match 202A repair
• Replace bushing at overhaul
• No machining required
34
Hubs
Production Bushing (-1)
 HC-SL-61-305 [pending]
– Production change for all
standard -1 hubs
• Already implemented in 113B
for all Bonanza specific item #
• SL305 addresses all
remaining standard -1 hubs
35
Hubs
TB-10 Inspection
 HC-SB-61-323: Hub Inspection [pending]
– Affects propellers installed on Socata TB-10
– ECI of “A” suffix hubs, similar to SB269
• Initial within 50 hours
• Recurring every 100 hours or annual
– Terminating actions:
• Hub Replacement with “B” suffix hub
• Oil fill IAW SL273 [pending]
36
Hubs
Oil-Fill
 HC-SL-61-273: Hub
Modification [pending]
– ~4500 hrs in field
– Only when directed
by Hartzell Service
Bulletin
• Machine hub bore &
breather holes
• Install bushing &
retainer ring
37
Hubs
Oil-Fill
 HC-SL-61-273: Hub
Modification [pending]
– Only when directed
by Hartzell Service
Bulletin
• New sealant at parting line
• Plugs instead of zerks
• Red-dyed oil-filled for crack
detection
38
Seals
Grease Leaks
 Silicone O-rings
– Grease leaks have
been a concern in
aluminum hub
propellers
– Suggestion from the
field for use of new
material
– Engineering analysis
for compatibility
completed
39
Seals
Grease Leaks
 Silicone O-rings
– Field testing in alum
models ongoing
– Over 30,000 SER
hours with NO leaks
– Already implemented
in production for many
models
 Successful seal is also
dependent upon a good
installation of the
appropriate wear strip
40
Seals
Grease Leaks
 HC-SL-61-293 rev. 1: Y
Shank Aluminum Blades
[Mar 12/10]
– Introduces C-3317-340-8
– Approved alternate to
quad seal
– Requires use of 0.010”
Teflon®
– Cost analysis in process
for production
implementation
41
Seals
Grease Leaks
 HC-SL-61-301:
 Supersedes all C-3317-340
[Mar 12/10]
– Introduces C-3317-340-8
– Requires use of 0.010”
Teflon® on alum blades
– Use existing C-3317-340
– Composite blades use
different wear strip
• No change required
– Production implemented
42
Seals
Grease Leaks
 HC-SL-61-303:
Supersedure in 1900D
Installations [Apr 9/10]
– Introduces C-3317-340-8
– May use existing
energizer ring + blade
seal in combination
43
Seals
Grease Leaks
 HC-SL-61-303:
Supersedure in 1900D
Installations [Apr 9/10]
– Energizer ring + blade
seal can not be mixed
with C-3317-340-8 in
same propeller assembly
– Production and overhaul
kit implementation is
complete
44
Seals
Grease Leaks
 HC-SB-61-321:
Replacement in PC-21
Installations [Jun 15/10]
– Introduces C-3317-341-8
and 103379-1 wear strip
– Required at next o/h
– Optional at disassembly
– Requires use of thicker
103379-1 wear strip
45
Seals
Grease Leaks
 HC-SB-61-321:
Replacement in PC-21
Installations [Jun 15/10]
– Energizer ring + blade
seal combination can not
be mixed with C-3317341-8 in same propeller
assembly
– Reporting required
– Production and o/h kit
implementation complete
46
Seals
Grease Leaks
 HD-SL-61-042:
 Supersedure for Do-328
Installations [pending]
– Introduces C-3317-341-8
and 103379-1 wear strip
– Requires use of thicker
103379-1 wear strip
47
Seals
Grease Leaks
 HD-SL-61-042:
 Supersedure for Do-328
Installations [pending]
– Energizer ring + blade
seal combination can not
be mixed with C-3317341-8 in same propeller
assembly
48
Spinner
 Known cracking issues
 Working to design a permanent fix by
application
49
Spinner
835-54(P) Replacement
 HC-SB-61-311:
Inspection of 835-54(P) Spinner
Assembly & Introduction of
New Spinner Assemblies
– Progression of document
• Original Issue:
1.D-5769-1(P) dome, filler
plate removal required
50
Spinner
835-54(P) Replacement
 HC-SB-61-311:
Inspection of 835-54(P) Spinner
Assembly & Introduction of
New Spinner Assemblies
– Progression of document
• Original Issue:
2. 102965(P) dome released
as supercedure to
unsupported D-5769-1(P)
– 102965(P) includes
bonded support
51
Spinner
835-54(P) Replacement
 HC-SB-61-311, Rev 1:
Inspection of 835-54(P) Spinner
Ass’y & Introduction of New
Spinner Assemblies
• Revision 1
1.D-5769-1(P) dome
uses field-installable
forward bulkhead &
spacers
52
Spinner
835-54(P) Replacement
 HC-SB-61-311, Rev 1:
Inspection of 835-54(P) Spinner
Ass’y & Introduction of New
Spinner Assemblies
No-Charge Warranty Components
53
Spinner
835-54(P) Replacement
 HC-SB-61-311, Rev 3:
New Composite Spinner Ass’y
Introduction
– Revision 2 (pending)
– Terminating Action
within 13 calendar
months/ 50 hours,
whichever first
54
Spinner
835-54(P) Replacement
 HC-SB-61-311, Rev 3:
New Spinner Ass’y Introduction
1.103585(F1) assembly with
composite dome (Mooney)
2. 835-58(P) assembly with
blunt, aluminum dome
(Comanche)
No Charge Warranty Coverage
55
De-Ice
 Hartzell de-ice components
– Working to convert legacy components to
Hartzell components
– Making design improvements along the way
• Your suggestions are welcome
• If you have found a difficult installation and/or have
design/installation suggestions please let us know
56
De-Ice
PC-12 Routing
 HC-SL-30-295 rev. 2:
Wire Harness and Boot
for PC-12 [Apr 9/10]
– Conversion to Hartzell
components
– Design improvements
– New routing required
– Expect similar
updates for similar
installations
57
Miscellaneous
TSN
 Questions on Time Since New of a propeller
– What parts to track time for
– What happens when components are changed out
 HC-SL-61-61Y rev. 3: Overhaul & Life Limits [Nov 13/09]
– Definition of Time Since New (TSN)
– Primary components = hub, blades, & life-limited parts
– Propeller assembly TSN = highest TSN primary
component installed
58
Miscellaneous
Cam Follower Retention
 HC-SB-61-320 [June 2010]:
Pitch Change Knob Bracket
– Affects HC-E5A-2 on
Pilatus PC-21
– Introduces new unit with
improved cam follower
retention design
59
Miscellaneous
Preload Plate Wear
 HC-SL-61-282 rev. 1, [Nov 09]:
Preload Plate Wear Limits
– E shank blade butt seal
released in 2005 to prevent
hub cavity grease migration
• Later reports identified wear
on the preload plate caused by
the new seal
60
Miscellaneous
Preload Plate Wear
 HC-SL-61-282 rev. 1, [Nov 09]:
Preload Plate Wear Limits
– Affects E shank lightweight
turbines and Y shank
compacts with composite
blades (excludes N shank)
– Preload plate inspection
criteria at overhaul
 What are you seeing in the field?
61
Miscellaneous
Feathering Spring
 HC-SL-61-291 [obs] →
HC-SB-61-324 [pending]:
Feathering Compression Spring
 Reports of feathering issues in
the field
– Unable to reach full feather
at shutdown
– Disassembly found
fractured feathering spring
62
Miscellaneous
Feathering Spring
 HC-SL-61-291 [obs] →
HC-SB-61-324 [pending]:
Feathering Compression Spring
– Affects HCB(4,5)(M,T)(A,N,P)(1,2,3,5)
– Introduces 102877 spring
as supercedure to A-3496
• New 102877 has flat
outer diameter and
improved fatigue life
63
Miscellaneous
Feathering Spring
 HC-SL-61-291 [obs] →
HC-SB-61-324 [pending]:
Feathering Compression Spring
– (new in SB324) At next
overhaul, requires
replacement of the A-3496
with new 102877
64
Status Updates
SB269 Program
 HC-SB-61-269 rev. 4: Hub Inspection [Nov 13/09]
– FAA approved AMOC to AD 2009-22-08
• AD 2009-22-08 superseded AD 2006-18-15
– AD requires initial inspection within 50 flight hours
• Contact local FSDO to discuss
– Retained 100 flight hour recurring inspection
• Removed ‘or annual inspection’
– Pricing program (within TBO) expires April 30, 2011
65
Technical Issues Review
 Documents go through writing, review, editing,
and approval – but still not perfect
– If you want clarification
– If you find an error
– If you have a suggestion
PLEASE CONTACT PRODUCT SUPPORT
66

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