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Technical Issues Review

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  1. Technical Issues Review Presented By: Michael Mayhill

  2. Technical Issues Review • Composite Blades • Aluminum Blades • Hubs • Seals • Spinner • De-ice • Miscellaneous • Status Updates

  3. 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?

  4. Composite BladesASC 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

  5. Composite BladesASC II • HC-SL-61-294: • Field Inspection and Minor Repair Criteria for N7605( ) blades [May 07/09] • Previously in Manual 135F only

  6. Composite BladesASC 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

  7. Composite BladesInspection • 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

  8. Composite BladesInspection • HC-ASB-61-306 rev. 2: • Inspections of N7605( ) • Effectivity is s/n specific to early production • 387 blades affected

  9. Composite BladesInspection • 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

  10. Composite BladesInspection • 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

  11. Composite BladesInspection

  12. Composite BladesInspection

  13. Composite BladesInspection • HC-ASB-61-306 rev. 2: Inspection of N7605( ) • UT equipment available for loan • Warranty coverage for UT at overhaul

  14. Composite BladesStaking Pins • Staking pins found sheared during standard engineering evaluation of high-time N7605( )blade • No performance issues noted • Design improvement with larger staking pins

  15. Composite BladesStaking 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

  16. Composite BladesStaking Pins Was B-5996-628 Ø=0.125” Now B-5996-640 Ø=0.1875” (Production)

  17. Aluminum BladesProduction 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

  18. Aluminum BladesProduction 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

  19. Aluminum BladesProduction 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

  20. Aluminum BladesNaCl 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

  21. Aluminum BladesNaCl 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

  22. Aluminum BladesNaCl 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

  23. HubsLubrication 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?

  24. HubsModification • 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

  25. Hubs1900D 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

  26. Hubs1900D 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

  27. Hubs1900D 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

  28. HubsBonanza/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

  29. HubsBonanza/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

  30. HubsBonanza/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

  31. HubsBonanza/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

  32. HubsBonanza/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

  33. HubsBonanza/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

  34. HubsProduction 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

  35. HubsProduction 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

  36. HubsTB-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]

  37. 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

  38. 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

  39. SealsGrease 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

  40. SealsGrease 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

  41. SealsGrease 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

  42. SealsGrease 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

  43. SealsGrease 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

  44. SealsGrease 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

  45. SealsGrease 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

  46. SealsGrease Leaks • HC-SB-61-321: Replacement in PC-21 Installations [Jun 15/10] • Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly • Reporting required • Production and o/h kit implementation complete

  47. SealsGrease 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

  48. SealsGrease Leaks • HD-SL-61-042: • Supersedure for Do-328 Installations [pending] • Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly

  49. Spinner • Known cracking issues • Working to design a permanent fix by application

  50. Spinner835-54(P) Replacement • HC-SB-61-311: Inspection of 835-54(P) Spinner Assembly & Introduction of New Spinner Assemblies • Progression of document • Original Issue: • D-5769-1(P) dome, filler plate removal required