Author: neilw

Lufthansa Technik has developed a new product for optimal care of older engine types through to their end of life in flight operations.

smart.life sets out to minimize the increased overhead requirement of aircraft engines, which experience shows occurs at their end of life, by taking advantage of various product components and synergy effects in maintenance.

“Engine repairs and overhauls are essentially approached in a different way with smart.life in the second half of their life cycle,” says Bernhard Krüger-Sprengel, Senior Vice President Engine Services of Lufthansa Technik. “Instead of a traditional overhaul, we follow the approach with smart.life of delivering thrust during this phase of the product life cycle – with the aim of making optimal use of an engine’s, modules or engine parts remaining life span.”

smart.life includes various technical and commercial elements: On one hand, this includes creating an individual workscoping for every engine as well as producing a reliable engine from two defective engines. Added to this are leasing models as well as the purchase of customer engines and immediate lease-back as well as pooling of the customer’s own spare engines.

Combining the existing opportunities in an optimized and tailored manner should allow synergy effects to be achieved and therefore savings to be generated for the customer. The respective customer situation, the fleet size, the required remaining life span and legal requirements are all considered in this context.

The need for more flexible management of engine maintenance for older engine types is also being driven by the current market situation. Various engine types are set to reach the end of their product life cycle in the short to medium term. The GE CF6-80, Pratt & Whitney PW4000, as well as the CFM56-5A/-5C from CFMI are initially in the new product’s focus. However, all engines that are entering the second half of their life cycle will be ultimately addressed in the long term by smart.life.

Baker Aviation, a full service aircraft maintenance, management and charter company in North Texas, is the exclusive distributor for the HOT-STOP ‘L’ Fire Containment Bag product line joins Industrial Energy Products (IEP) to announce that 1500 units are now aboard aircraft based around the world.

“Exceeding 1500 bags is a major milestone for us,” Tom Connolly, president of IEP, the manufacturer of the HOT-STOP ‘L’ bags, says. “Our HOT-STOP L customers are Fortune 100 flight departments, international airlines and aircraft manufacturers’ that recognize the value of our tested and burn certified products. Now we will accommodate users that feel the need to follow the water application philosophy. Our bags will safely contain potential in-flight battery runaway without water, and now we have a process to accomplish this with a water application. Keep in mind that many mobile devices today are waterproof and in many situations an overheated device may not be in full runaway nor require full water saturation. Once the HOT-STOP bag is soaked with water, the layers of fire containment materials will be compromised so the customer will need to replace it,” added Connolly.

The HOT-STOP ‘L’ Fire Containment Bag safely contains fires, explosions and smoke emissions from Lithium Ion powered devices as well as any combustible item aboard an aircraft. These distinctive HOT-STOP ‘L’ bags have been successfully tested twice in live fire evaluations at the FAA Technical Center in Atlantic City, New Jersey and further independently fire tested by flight departments.

“This is an exciting 1500 milestone and the response we are seeing from the business aviation sector is impressive,” stated Ray Goyco, Jr. President and COO at Baker Aviation. “The recommendation to use water to cool down these devices, originated many years ago with limited validation but we can accommodate this philosophy with our proven technology. The HOT-STOP ‘L’ bags help flight crews be proactive when dealing with a potential runaway, before there is smoke, fire or an explosion. Our product is tested without the need for water, which minimizes life-threatening smoke emissions and provides a time-saving means to safely contain a device in question, without hesitation and without prematurely destroying the passenger’s device with water,” added Goyco.

The distinctive fire containment bag is different from other products on the market and can be used to store a laptop, tablet, or smart phone when not in use, contain an overheating device, or contain one that is in full thermal runaway. The bags are made up of multiple durable fabrics with a felt inner core that has a 3200ºF melting point which is sandwiched between two outer layers that have a 2080ºF melting point and are proven to absorb the energy and fire while minimizing the escape of smoke, sparks and flames.

The HOT-STOP line of fire containment bags can be customized to fit the operator’s need and is currently offered off the shelf sizes for smart phones, passenger or flight deck tablets, and laptop computers. Tailored defibrillator device covers are also available to safely contain these lithium ion battery powered devices. Due to larger devices being brought on board, the new oversized bag was recently introduced. At 25” wide x 22” high, it is designed to contain laptops and all-in-one portable computers up to 19” wide x 14” wide x 2” in thickness.

Recently, Baker Aviation announced a surrender rebate program for other competing bags. Baker is offering a $100, discount when customers surrender any other fire containment brand of bag at time of purchase of a new, proven and tested HOT-STOP ‘L’ lithium ion fire containment bag. For more details please contact Ray Goyco, Jr. at Baker Aviation at Ray@Baker-Aviation.com.

Butler National Corporation announces the availability of two new component solutions for sale for Learjets. Incorporating new technologies, Butler National designed, manufactured and obtained Federal Aviation Administration Supplemental Type Certificate (STC) approval of a replacement rate sensor for use by the autopilot on the roll axis and yaw axis of the applicable Learjet 31/35/35A/36/36A/C-21A and 55 Series airplanes, and on the yaw axis on the Learjet Model 24/25/28/29 Series airplanes. The replacement rate gyro sensor is approved for installation under STC number ST02416SE. The new rate gyros are available for immediate sale and shipment.

Butler National also added another new STC to replace the existing stall warning accelerometer for the Learjet 24/25/28/29 Series airplanes and Learjet 35/35A/36/36A airplanes with the FC-200 autopilot. The new vertical accelerometer is STC (STC number ST02417SE) approved as an alternate means of compliance for airworthiness directive 82-01-05. The new vertical accelerometer is currently available for sale and shipment from Butler National.

Parts obsolescence is a never ending battle in the airplane business. Many aircraft, like Learjet 20 and 30 series airplanes are reaching their 40th plus year of operation. This makes replacement part acquisition a significant challenge. One Butler National research and development focus is providing new part alternatives to obsolescence issues with cost-effective new replacement parts for the Learjet airplanes.

The new Butler National rate gyro sensor solution uses an upgraded solid-state technology and provides a noticeable improvement in yaw damper operation compared to many of the old and tired oil-filled rate gyros.

“We are pleased to continue achieving our goals to offer new components and system upgrades for sale to operators of legacy Learjets. We believe the new replacement rate sensor gyros will offer enhanced reliability and improved performance,” says Clark D. Stewart, President and CEO. “An operational yaw damper is required for dispatch of Learjet 20 and 30 series airplanes, unless they are equipped with our Avcon Delta Fins. The new yaw damper sensor provides a noticeable and quicker damping response to turbulence inputs than is experienced with the classic oil-filled devices. We believe passengers will have a better ride experience with the new Butler National yaw rate gyro sensors. The replacement yaw rate gyro may be used in either the primary or secondary yaw damper system with the applicable model Learjets. Through Butler Avionics, we are offering a special introductory price to exchange an existing rate gyro for the new solid state Butler National Rate Gyro at a price of $ 4,500.00.”

“We have an FAA approved STC solution for a new replacement stall warning vertical accelerometer in the Learjet 20 and 30 series airplanes, ” Stewart says. He added: “We have had numerous requests to assist with technical obsolescence solutions in Learjets, and the replacement vertical accelerometer is another prime example of combining our aviation experience with our technical expertise. We are working to provide Learjet customers new parts with new technology.”

“We stepped up to provide reasonable solutions to keep these aviation ‘workhorses’ operational. We offer noise solutions, avionics solutions, and parts obsolescence solutions. We believe in these aircraft, and we will continue to support these Learjets in the future,” says Stewart.

Flight Safety Foundation (FSF) will be holding the Approach and Landing Accident Reduction (ALAR) InfoExchange and the Maintenance and Engineering Safety Forums the week of February 10, 2015 in Singapore. FSF and the Singapore Aviation Academy are jointly organizing these events.

The ALAR InfoExchange, scheduled for February 10 and 11, will provide a platform for the discussion and sharing of information of ALAR-related issues including stabilized approaches, go-around decision making and execution, air traffic management (ATM) contribution to go-around safety, safe landing guidelines, technology and other runway safety strategies.

On February 12-13, the inaugural Maintenance and Engineering Safety Forum will focus on some of the key safety issues and challenges faced by the MRO industry relating safety as perceived and managed by maintenance organization,; identifying workplace challenges both for the aviation industry regulators associated with human factors in aviation maintenance; and harnessing of new technologies to enhance maintenance and engineering safety.

“Both of these meetings provide an excellent opportunity for a sharing of the latest ideas in two key focus areas in the industry,” stated FSF president and CEO, Jon L. Beatty. “An event like this allows for a robust discussion between different segments of the industry – allowing a better understanding of how all the pieces can work together.”

Both meetings will be held at the Singapore Aviation Academy. Full information, including registration, hotel and travel information can be found on the FSF website at http://www.flightsafety.org/Singapore2015

Walter Surface Technologies has launched the ZIPWHEEL cutter, a powerful cordless cutter that can drive a 6” cutting wheel.

The ZIPWHEEL cutter is specifically designed for metal workers who are consistently on-location without access to a power supply. This unique tool utilizes the latest battery technology and features an exclusive Ventilated Charging System. The system comprises of an 18V/5.2Ah battery, the strongest battery on the market today, allowing workers to perform more cuts between charges. In addition, the ventilated charging station quickly charges the battery while also extending its life by keeping it cool during the charging process, the company says.

The ZIPWHEEL cutter provides DYNAMAX electronics for RPM control and consistent speed under load, bevelled gears to reduce noise, and a front retaining plate and rear bushing to prevent misalignment and reduce vibration.

“We’ve incorporated the latest technology to engineer the ZIPWHEEL cutter and produce this one of a kind heavy-duty and lightweight cordless cutter” said Stephane Drainville, product manager at Walter Surface Technologies. “This one tool will reduce downtime by allowing users to make more cuts between recharges. And with the Ventilated Charging System, battery-life is extended too. All of which leads to reduced production costs. Furthermore, with the ability to use a 6” cutting wheel on a cordless cutter, it will easily increase performance and production rate. It is the ultimate tool for on-location workers.”

The ZIPWHEEL cutter is designed to be used with Walter’s high performance ZIP family of cutting wheels. By combining both products together, users have the perfect cutting technology in hand.
The ZIPWHEEL cutter is available in 4½ / 5” and 6” diameters starting January 2015 in an exclusive starter kit for a limited-time. For more details on the ZIPWHEEL cutter contact your local representative or distributor.

FL Technics is further expanding its client base in Europe and Asia by signing a Base Maintenance agreement with a Turkish low-cost carrier Pegasus Airlines. Under the agreement, FL Technics will provide Base Maintenance support for the carrier’s Boeing 737 NGs.

Pegasus Airlines, the second largest carrier in Turkey, has already delivered its first Boeing 737-800 aircraft to FL Technics’ base maintenance facilities at Kaunas International Airport, Lithuania. The aircraft will undergo a comprehensive set of maintenance works under a 6 year C-Check program, including structure and composite repairs, NDT, technical defect rectification, etc.

Additional aircraft will reach FL Technics’ Kaunas MRO base in the nearest future. All maintenance works for the first group of aircraft are expected to be concluded by May 2015 in order for Pegasus Airlines to be fully prepared for the upcoming summer season.

“It is an exceptional joy to win the trust of a new customer, particularly from such a fast growing market as Turkey. We are delighted that Pegasus Airlines have entrusted us with the support of their actively developing fleet. Since we have reached a mutual understanding concerning the carrier’s aircraft support in the second half of the year as well, we certainly hope that the new cooperation will eventually develop to a long-standing and comprehensive partnership between our companies,” says Zilvinas Lapinskas, the CEO of FL Technics.

GE Aviation has been awarded a three-year (2015-2017), $460 million Performance Based Logistics (PBL) contract from the U.S. Navy covering the repair, replacement and program support for F414 engine components for the F/A-18 E/F and EA-18G Growler aircraft.

This multi-year procurement arrangement is an availability-based contract providing operational readiness requirements for the F414 fleet through the Navy’s Fleet Readiness Centers West (Lemoore, CA) and Southeast (Jacksonville, FL).

“We are grateful for the opportunity to continue our successful collaboration with the Navy to provide a comprehensive, integrated, and cost-effective solution ensuring F414 readiness for our customer,” said Scott Snyder, GE F414/F404 PBL Director.

This contract builds on the success of a series of previous F414 PBL contracts dating back to 2002. Since the introduction of PBLs, the Navy has realized significantly lower acquisition costs with improved readiness while GE added considerable value to the military aftermarket.

In addition to the Lynn plant, GE Supply Chain facilities in Hooksett, NH; Rutland, VT.; Wilmington, NC; and Madisonville, KY will provide parts for this PBL contract.

Twin F414 engines power F/A-18E/F Super Hornets and EA-18G Growlers. The F414 engine for the F/A-18E/F and EA-18G is rated at 22,000 pounds (98 kN) thrust and is in the 9:1 thrust-to-weight ratio class. The U.S. Navy has taken delivery of over 1,000 F414 engines with more than 1.5 million engine flight-hours accumulated to date.

The F414 has also been selected as the powerplant for growth versions of the Saab Gripen and India’s Light Combat Aircraft (LCA), and is a candidate for other combat aircraft under development.

PPG Industries has expanded its line of SEMCO sealant removal tools with ergonomically-designed scrapers that improve efficiency of aerospace sealant removal and reduce operator fatigue.
According to Dillon Desai, PPG global market development manager for packaging, 10 scrapers have been designed for use by hand for standard sealant removal as well as more difficult and specialty applications such as removal of sealant around fasteners, fillet seals and other hard-to-reach areas.

“With these new ergonomic Semco tools, aircraft workers and maintenance personnel can select the scraper that best meets their needs to make sealant removal easier,” Desai said. “Semco packaging and application systems aid the aerospace industry with efficient, cost-effective and easy-to-use packaging for mixing, dispensing and applying chemicals. With these new scrapers, we broaden our offerings for sealant and adhesives removal to provide a more complete resource.”

Five tools are made of glass-filled nylon materials for more difficult operations, while five tools designed for standard sealant removal by hand are made of CELCON acetal copolymer (POM). “The tools are designed for more rigorous operations and will last longer than those made with more traditional materials,” Desai said. “CELCON POM is often preferred by aircraft manufacturers because it offers the end-user more control when removing sealant and will not scratch or score aluminum substrates.”

The tools have a variety of widths from 1/4-inch to 3 1/2-inch with eight scrapers having straight ends, one having an angled end and one with a pointed-tip design. An added benefit is that these tools can be sharpened for continued use.

New Semco aerospace sealant removal tools are available through PPG application support centers.