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Ben Hargreaves Mar 03, Aircraft flight control surfaces—ailerons, rudders, elevators, flaps and slats—are subject to considerable wear and tear in the course of everyday operation. Control surfaces are usually adhesively bonded composite or aluminum honeycomb sandwich structures. These components can suffer from damage caused by runway debris, hailstones, lightning strikes or tools dropped during maintenance.
On composites, low-velocity impact damage sometimes escapes visual inspection, meaning nondestructive testing NDT also must be used to determine the damage to a flight control surface. Typical repairs to flight surfaces include metallic and composite patches. Like other MROs, it focuses on new technologies for nondestructive testing such as thermography. Companies that provide tooling for aerospace operations have recognized that MROs are benefiting from new types of technology, and they are introducing equipment that speeds up and automates repairs for composites, including flight control components as well as curved surfaces and the fuselage.
The company has developed a mobile robot equipped with software needed to recognize free-form 3D surfaces. For airframe scarfing, the robot is placed on a stand and is attached to the carbon-fiber composite component with suction cups. Software allows the mobile robot to process 1, X 1,mm Machine toolmakers DMG Mori and Sauer also have introduced mobile five-axis aerospace milling units to carry out repairs on aerospace composite components.
These lightweight machines feature vacuum suction feet and moveable ball joints and mounting arms. They can be clamped to even surfaces such as wings for flight surface repairs, or to components with radii and complex contours such as frame elements on the fuselage of an aircraft. The five-axis control offers PC-based operation via a touchscreen for the user.
The machine allows the user to define the damaged area, the machining task, laser surface measurement of the workpiece, and creation of the final file. It provides maintenance, structural repairs and modifications for narrowbody airliners—typically Airbus As and Boeing s. Often, flight control surfaces will be removed and placed in a workshop and an insert made, or an entire section replaced. The time taken to cure a composite repair to a flight control surface using this technique can be reduced from 24 hr.
Many flight control surfaces feature an aluminium frame with a composite overlay. The trailing edges are often composites with honeycomb sections embedded in them. If the honeycomb has been damaged, it is removed and a new honeycomb is inserted with resin, then overlaid with fiberglass or carbon-fiber skin, explains Anderson.
Cardiff Aviation. Cardiff Aviation uses numerous NDT techniques such as eddy current, X-ray and visual inspection to determine the full extent of flight control component damage. Cardiff Aviations uses NDT techniques such as eddy current and X-ray analysis to determine the full extent of the damage, as well as visual inspection. The airline or lessor wants its aircraft back in service as quickly as possible, earning money.
We want the next aircraft in as quickly as possible. So for both parties, rapid turnaround is certainly the objective.
Physical and NDT examinations may reveal water within the flight control surfaces, which must be drained. That creates disbonding within the structure. Sections are cut out and new surfaces with fresh skins inserted. The operation must be vacuum bagged, a process in which pressure is applied to the repair in order to improve its consolidation by sealing a plastic film over the wet laid-up composite and onto the tool.
He says the company is developing new NDT techniques to facilitate the repair process. It also continues to work with Sunaero to look at technology that may speed up the repair of flight control surfaces and other components. Usually there is. For older aircraft, such as those serviced and maintained by Cardiff Aviation, scribe marks—damage to aircraft surfaces caused by the use of sharp tools used during paint and sealant removal—are often an issue, Anderson adds.
See how MROs are speeding up flight control surface repairs. Hide comments. Text format Comments Plain text. Web page addresses and e-mail addresses turn into links automatically.
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Aircraft maintenance - Wikipedia
Aircraft maintenance is the performance of tasks required to ensure the continuing airworthiness of an aircraft or aircraft part , including overhaul, inspection, replacement, defect rectification, and the embodiment of modifications, compliance with airworthiness directives and repair. The maintenance of aircraft is highly regulated, in order to ensure safe and correct functioning during flight.
In civil aviation national regulations are coordinated under international standards, established by the International Civil Aviation Organization ICAO. The ICAO standards have to be implemented by local airworthiness authorities to regulate the maintenance tasks, personnel and inspection system. Maintenance staff must be licensed for the tasks they carry out. Aircraft maintenance in civil aviation generally organized using a maintenance checks system, which are periodic inspections that have to be done on an aircraft after a certain amount of time or usage.
A Power by the Hour program provides budget predictability, avoids installing a loaner during repairs when an aircraft part fails and enrolled aircraft may have a better value and liquidity. This concept of unscheduled maintenance was initially introduced for aircraft engines to mitigate engine failures.
In the s, Rolls-Royce plc reinstated the program to provide the operator with a fixed engine maintenance cost over an extended period of time. Operators are assured of an accurate cost projection and avoid the breakdowns costs; the term is trademarked by Rolls-Royce but is the common name in the industry. Jet Support Services provides hourly cost maintenance programs independently of the manufacturers. At the completion of any maintenance task a person authorized by the national airworthiness authority signs a maintenance release stating that maintenance has been performed in accordance with the applicable airworthiness requirements.
In the case of a certified aircraft this may be an Aircraft Maintenance Engineer or Aircraft Maintenance Technician , while for amateur-built aircraft this may be the owner or builder of the aircraft.
Each Contracting State is expected to use in its own regulations the one it prefers. However different countries use these terms in different ways to define their individual levels of qualification and responsibilities. This regulation establishes four levels of authorization:.
Its is projected to grow at 4. Insourced maintenance can be inefficient for small airlines with a fleet below 50—60 aircraft. They have to either outsource it or sell its MRO services to other carriers for better resource utilization. Over the course of the engine life it is possible to put value back in by repair and overhaul , to sell it for its remaining useful time, or to disassemble it and sell the used parts, to extract its remaining value. Its maintenance value includes the value of life-limited parts LLPs and the time before overhaul.
The core value is the value of its data plate and non-life-limited-parts. After some time the maintenance reserves exceed the aircraft lease. Between and , 5, spare airliner engines will be required with at least half leased. Airbus has indicated that data diagnostics could put an end to aircraft unscheduled grounding for fault repairs around , supported by big data and operational experience.
Data or monitoring can tell that some parts do not need a scheduled check, but a full transition to this model will need much greater experience.
A Britten-Norman Islander retrofitted with electric propulsion should be demonstrated by by Cranfield Aerospace before commercial service in From Wikipedia, the free encyclopedia. Main article: Aircraft maintenance checks. Archived from the original on 27 December Retrieved 9 December Archived from the original on 18 May Knowledge at Wharton. Feb 21, Bloomberg Businessweek. Transport Canada. Licenses and ratings for personnel other than flight crew members. ICF International.
Aviation Week Network. Jul 12, Aug 16, Comparing civil, helicopter, business aviation and military MRO forecasts for MRO Network. May 30, Aviation Week network. Arvai January 19, Aviation Week Intelligence Network. Spanovich Jan 10, November 23, Retrieved May 20, Journal of Electronic Imaging. Jovancevic, I. Viana, T. Sentenac, J. Orteu and S. Categories : Aerospace engineering Aircraft maintenance Aircraft engines Aircraft finance Maintenance.
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