New Issues in Repair Station Security

by Jason Dickstein

The long-awaited TSA Repair Station Security Rule—a rule a decade in the making—was finally issued in January of this year. The new rule was authorized by Congress under the repair station security statute (49 U.S.C. § 44924). As with any new rule, the TSA repair station security rule will mean a number of changes about which repair stations will need to be aware.

One of the primary effects of the repair station security statute was to bar the FAA from issuing any new foreign repair station certificates until TSA security audits were completed for existing stations. But because TSA had not issued its rule, TSA was unable to conduct any audits because it did not have any standards to audit to. Now that the rules are out, TSA has begun auditing repair stations for compliance with the new security rules. After TSA has completed its audits of all existing repair stations, the FAA may once again start issuing foreign repair station certificates. The FAA has been prevented from issuing foreign repair station certificates for more than five years, so the ability to begin issuing certificates could mean good news for non-US repair stations as well as for U. S. repair stations seeking to expand their operations overseas.

With the advent of new audits and the issuance of new foreign repair station certificates, there are several issues about which business owners and employees should be vigilant.

First, the new security regulations apply quite broadly. The regulations apply to those repair stations certificated by the FAA under Part 145 that are on or adjacent to airports and that have means of access permitting aircraft of 12,500 MTOW to move to the repair station. The exception to this rule is for repair stations located on a U.S. or foreign government military base. Additionally, the rule is applicable to all aircraft over the threshold, not just N-registered aircraft. The key element is access; although all repair stations are subject to inspection as provided in the rule and to Security Directives should there be a security need, the rule text requires only certain repair stations to carry out security measures on a regular basis.

 

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Mexican Navy Places Order for Beechcraft T-6C+ Trainers

Beechcraft Corporation, part of the Textron Aviation segment of Textron, has received an initial order from the Mexican Navy Secretaría de Marina (SEMAR) for two T-6C+ military trainers. This purchase represents the first step in modernizing the Mexican Navy’s fixed-wing aviation fleet and follows a recent expansion of the Mexican Air Force training fleet to include 12 T-6C+ aircraft. The Navy trainers are scheduled for delivery in the summer of 2014.

In addition to the aircraft, Beechcraft’s Global Mission Support organization is working on a second contract with SEMAR that is expected to include two years of parts support, training for pilots and mechanics, and the placement of Field Service Representatives who will provide technical expertise and training to maintenance personnel.

“We are pleased to expand the reach of the T-6C+ to a second military fleet customer in Mexico with this initial order from the Mexican Navy,” said Russ Bartlett, senior vice president, Defense. “SEMAR not only recognizes the value of a proven, reliable airframe with the T-6C+ in standing up its new training capability, but this selection also acknowledges the significant benefits our Global Mission Support team offers in providing on-the-ground service, support and training for the fielded aircraft.”

The T-6C+ features a hard-point wing, Heads-Up Display, Up-Front Control Panel, an integrated glass cockpit and an advanced Esterline CMC Cockpit 4000 avionics suite that greatly expands advanced training opportunities. The systems are integrated with a Hands-On Throttle and Stick (HOTAS), providing the student pilot and instructor with a simpler interface to the digital cockpit. The CMC Cockpit 4000 avionics suite is the first in its class to incorporate a fully integrated and FAA-certified dual FMS/GPS navigation suite that meets the required navigation performance standards for current worldwide airspace equipment. The open architecture design of the Cockpit 4000 provides the flexibility to expand capabilities and continuously meet current and future training needs.

In addition to accommodating instruction in instrument flight procedures and basic aerial maneuvers, the T-6 delivers world-class training capability that is appropriate for teaching the most basic introductory flight training tasks through the more challenging and complex advanced training missions that could previously be accomplished only in far more expensive jet aircraft. The T-6 has been used to train pilots, navigators, and weapons systems operators from more than 20 countries around the world. To date, Beechcraft has delivered more than 825 T-6 trainers, which have amassed more than 2.2 million flight hours.

New Technology Pulls Savings from Air

ACE192Liquid-nitrogen tanks on the flightline will become a thing of the past at Langley Air Force Base. Maintenance technicians instead will soon use machines that pull nitrogen from the air around them for servicing the 1st Fighter Wing’s aircraft and missile systems. The 1st Equipment Maintenance Squadron’s aerospace ground equipment shop has a dozen of the new self-generating nitrogen-servicing carts and “the folks on the flightline are anxious to use them,” said Staff Sergeant Dominic Bartholomeo III, a trainer with the AGE shop.

Three reasons stand out: reliability—the nitrogen can be produced on demand and never runs out; safety—no high-pressure bottles to transfer; and economy—the carts pay for themselves quickly and should last many years.

Nitrogen is used “to service certain aircraft systems because it’s an extremely clean inert gas,” explained Chief Master Sgt. Cindy McNally, 1st Logistics Group chief enlisted manager. “It doesn’t contain oxygen or water, both of which introduce corrosion into systems.”

The carts are fully automatic and operate in all types of climates, Bartholomeo said. They draw in the ambient air, remove the impurities and store the nitrogen as a gas. “We’ll be getting totally out of the liquid-nitrogen business,” he said.

Use of the new carts will save weight on deployments because they don’t need ventilation kits as the liquid-nitrogen carts do. Another benefit is ease of maintenance: Filters will be replaced about every six months, which fits right in with AGE’s standard periodic-inspection procedures.

Able Aerospace Named Exclusive Distributor by Northwest Dynamics

Able Aerospace Services announced that they have been named as the exclusive distributor for Northwest Dynamics’ pending PMA line of Bell Rotor Brake components and assemblies. This agreement allows Able to provide operators of Bell 206 & 407 helicopters a cost-effective alternative for parts and assemblies related to rotor brakes for these models.

Northwest Dynamics, Inc. (NDI) is the Original Equipment Manufacturer supplier of Bell Rotor Brakes and prior to this agreement with Able, has never offered these parts at an aftermarket level. “Partnering with Able to provide these parts for the aftermarket was an easy decision,” said William Kelly, Northwest Dynamics’ president and CEO. “Able’s reputation in the industry and their solid experience in rotorcraft PMA makes this a great collaboration that will benefit Bell operators worldwide.”

Able will stock and handle distribution of NDI’s Rotor Brakes and components for Bell 206 and 407 helicopters. “Operators of these helicopter types can expect significant savings and increased availability of these parts over the OEM sources, as a result of this agreement. We are extremely proud to be the distributor of choice for Northwest Dynamics, Inc. and their proprietary rotor brake parts for the Bell 206 and 407,” said Anthony Saenz, president of Able. “Adding NDI’s rotor brake parts to our over 8,000 safe, certified PMA parts and component repairs means that fleet operators and owners can save tens of thousands of dollars on parts that are of the same fit, form and function as new OEM parts.”

Hartzell’s TBM Composite 5-Blade Swept Prop Earns STC

Hartzell Prop251Hartzell Propeller has received Federal Aviation Administration Supplemental Type Certificate (STC) approval for the company’s advanced swept airfoil structural composite five-blade propeller to be installed on TBM 700/850 aircraft. Hartzell already has taken orders for the advanced propellers and deliveries to TBM owners are expected to begin shortly.

“Our new propeller design for the TBM turboprop results in faster takeoff acceleration, higher cruise speeds and better climb, along with less noise,” said Joe Brown, president Hartzell Propeller.

“Carbon composite, due to its incredible strength and light weight, allows Hartzell’s design group the freedom to optimize blade chord thickness and sweep while still achieving maximum strength. That’s the key: thin, light and strong, leading to unmatched performance,” he added. “The strong structural composite construction of these carbon fiber blades and their sleek aerodynamic design boosts the TBM’s already impressive performance to an even higher level.”

Hartzell says with the new propeller, the TBM’s takeoff acceleration from zero to 90 knots is 10 percent faster than with any other available propeller. Hartzell’s new propeller also provides for a couple hundred-feet-per-minute faster climb rate. Cruise is two knots faster than the Hartzell four-blade metal prop, and a full five knots faster than a less-advanced five-blade wood-based propeller option. The new Hartzell five-blade prop is also significantly quieter in the cabin and in the pattern.

Hartzell’s proprietary resin-injected carbon fiber blades are five to 10 times stronger than beech wood and spruce construction. The thinner airfoil, which is possible due to carbon fiber’s greater strength, makes the improved TBM performance possible.

The new five-blade design features a state-of-the-art composite wedge retention into its stainless steel alloy shank rather than the more rudimentary aluminum and lag screw construction used in lower performing propellers. Hartzell incorporates an innovative nickel erosion mesh and field replaceable nickel-cobalt erosion shield to prevent foreign object damage.

Hartzell received FAA and European Aviation Safety Agency (EASA) Type Certificate (TC) approval for the propeller in 2013. Hartzell offers the new prop with a “Plus 3” warranty, which covers the propeller for a full three years or 1,000 hours and a 3,600-hour/six-year TBO (Time Between Overhaul). The new propeller is available directly through Hartzell’s Top Prop conversion program or through DAHER-SOCATA’s distributor network.

AAR to Provide Component Repair and Management for Air Contractors

AAR has been awarded a three-year contract from Ireland-based Air Contractors Ltd. to provide component repair and management services for Boeing 757 aircraft operated by Air Contractors in a new cost-per-flight-hour program.

AAR will repair, overhaul, provision and supply components for Air Contractors’ base and line stations. Through increased component availability, AAR will be able to provide faster turn times and reduce repair costs. The work will be performed by AAR’s Aviation Supply Chain group, leveraging the Company’s diverse component repair and inventory management experience and capabilities.

“We were able to offer a flexible, high-value solution to Air Contractors that enables them to ensure high levels of service in support of its expanded transatlantic service,” said Carl Glover, Vice President of European Sales for AAR’s Aviation Supply Chain group. “We appreciate the confidence Air Contractors has shown in us with this new program and look forward to contributing to its efficient operations.”

AAR’s Aviation Supply Chain group offers a full range of products and services, from aftermarket airframe and engine parts to complete end-to-end supply chain management programs. AAR maintains one of the industry’s most extensive inventories of airframe and engine components and is one of the largest providers of flight-hour support. Capitalizing on its international network of distribution and repair centers, and cutting-edge tracking technology, AAR expedites delivery of products and services and customizes solutions for airline, MRO and OEM customers around the world.

Chromalloy Completes First Delivery of RR Trent XWB Components

Chromalloy announced that it has delivered the first seal segment carrier components to Rolls-Royce for the new Trent XWB aircraft engine.

“As a supplier for the new Trent XWB engine, Chromalloy has delivered our first seal segment carrier components to the manufacturer’s production line,” said Carlo Luzzatto, president. “The components were cast at a Chromalloy investment foundry and machining was performed at a manufacturing center in the company’s global network.”

Chromalloy produced the components on schedule as part of a multi-year contract for the supply chain of the new Trent XWB engine–a next generation, fuel efficient power system scheduled to enter service in mid-2014.
“Chromalloy is a total solution provider for critical components for power systems, offering make-complete parts from design and engineering services through casting and machining,” Luzzatto said.

The company is a long-time supplier to Rolls-Royce, providing repairs and services for the components found in the gas path or hot section of commercial and military aircraft engines. Contracts include services for the Trent and RB series engines, and others.

ICF International Names Vivek Saxena Vice President

ICF International, a leading provider of consulting services and technology solutions to government and commercial clients, has named Vivek Saxena to the position of vice president for ICF SH&E, which provides professional services in the aviation and aerospace fields.

Saxena has more than 20 years of experience in aerospace manufacturing operations, supply chain management and engineering program management. He will head up and strengthen ICF SH&E’s consulting work in the operations and supply chain practice, and enhance its five decades of successfully assisting airline, aerospace and travel companies.

“Vivek brings deep domain knowledge and leadership experience in aerospace operations and supply chain to ICF,” said Sergio Ostria, executive vice president for ICF International. “He will be a great asset to ICF’s continued growth in the international aerospace market.”

Prior to joining ICF, Saxena held several senior positions, including general manager, at Pratt & Whitney, a United Technologies company, for more than a decade. While there, he transformed shop operations, supply chain performance, cost reduction, new product introduction and implemented production ramp up processes. He led the company’s initiative to ascertain supply chain readiness for the Geared Turbofan and also led the war-on-cost in the multi-national supply chain for the Joint Strike Fighter engine. His work on new product introduction was published as a Harvard Case Study, which earned him a U.S. patent.

Saxena has a bachelor’s degree in engineering from the Indian Institute of Technology, India, a master’s degree from the University of Minnesota, United States, and a doctorate in aerospace engineering and math from the University of Cambridge, UK.

Cessna Offers Alpine Edition for Citation CJ2+

CessnaAlpine251Cessna Aircraft Company announced an upgrade program for the company’s successful Citation CJ2+ business jet. The new Alpine Edition CJ2+ modification package from Cessna includes the installation of a Garmin G3000 avionics suite—making the jet compliant with Next Generation (NextGen) requirements. In addition to the avionics upgrade, the Alpine Edition CJ2+ features new pressurization and environmental systems, the latest diagnostics systems, and a redesigned cockpit.

“The Alpine Edition CJ2+ is just one more example of Cessna’s continued investment in its products and services,” Matt Wild, Cessna Alpine Edition program manager, says. “With customers responding very positively to Garmin G3000 avionics and its touch control interface, we developed this program centered around putting the G3000 along with other system updates on an existing CJ2+ aircraft. The engineering flight test program is underway, with certification expected this summer and deliveries to start soon after.”

In addition to the Garmin G3000 avionics suite, the Alpine Edition includes increased access to the cockpit with the removal of seven inches from the legacy pedestal, improved turbulence detecting weather radar, TCAS II, advanced Terrain Awareness Warning Systems (TAWS), a wireless media server, Garmin integrated cockpit and cabin Iridium phone, and high speed Internet capabilities from Aircell. The Alpine Edition CJ2+ package includes the installation of automatic dependent surveillance-broadcast (ADS-B) capabilities, bringing the aircraft in compliance with this aspect of NextGen air traffic control requirements. Alpine Edition will also offer exclusive exterior paint schemes and interior packages as optional upgrades.

Cessna is offering the Alpine Edition modification at the company’s U.S. Citation Service Centers. Cessna is collaborating with Duncan Aviation to obtain the necessary Supplemental Type Certification from the Federal Aviation Administration (FAA) for the G3000 component of this new upgrade.

New 3D Manufacturer Titanium Components Breathes Life Military Aviation Death Spiral

There is a “Catch-22” irony that plagues defense industry budgets; the more money spent on aging aircraft, the less money there is to buy new aircraft. It is a situation that will get worse before it gets better. According to a recent news story in Defense Industry Daily, “The current US Air Force fleet, whose planes are more than 26 years old on average, is the oldest in USAF history. It won’t keep that title for very long. Many transport aircraft and aerial refueling tankers are more than 40 years old—and under current plans, some may be 70–80 years old before they retire.” As one senior military officer told CBS News recently, “Military aviation is in a death spiral.”

As the fleet ages and consumes all of the available replacement parts, maintenance, repair, and overhaul (MRO) operators face difficult financial choices in controlling their costs: either replicate titanium components from scratch through a lengthy and costly remanufacturing effort, or delay those expenses by cannibalizing other aircraft for “used” replacement parts, thereby decreasing the reliability of repaired aircraft while rendering some aircraft un-flyable. Fortunately, a US-based company has developed a manufacturing technology that offers a brighter cost-saving future for the replacement parts industry.

Additive Manufacturing Process
An exciting and cost-effective manufacturing technology is revolutionizing titanium parts manufacturing for the aviation, aerospace and defense industries. CalRAM fabricates three-dimensional, near net shape components by melting titanium (and other metal) powders one-layer at a time using an electron beam. Employing EBM machines built by Arcam, CalRAM’s tool-less additive manufacturing technology has the ability to rapidly create solid titanium objects faster and with less cost than traditional methods. Located in Simi Valley, just north of Los Angeles, CalRAM is the only independent AS9100C certified, EBM-based manufacturer in the United States. Offering this technology to MROs and other suppliers in the aviation and aerospace industries, the company has been producing titanium components for airframe primes and gas turbine engine aircraft manufacturers for almost a decade.

 

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