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CORROSION
Airborne Chemical Cling-Ons
Helicopter Maintenance —
A Personal Perspective
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CORROSION
Airborne Chemical Cling-Ons
Helicopter Maintenance —
A Personal Perspective
New to Part 107?
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8 DEPARTMENTS
The Doc is In 6, 22
Editorial Director 30
Editorial Director
Joe Escobar | 920.747.0195
jescobar@HelicopterMaintenanceMagazine.com
Contributing Writers
Mike Broderick, Mario Pierobon,
16 18
Kevin Stewart
Publisher
Greg Napert | 608.436.3376
gnapert@HelicopterMaintenanceMagazine.com
FEATURES Director of Sales/Production Coordinator
Bob Graf | 608.774.4901
Airframe 8 bgraf@HelicopterMaintenanceMagazine.com
Corrosion
Marketing/Sales
Rotordoc LLC — Mike Broderick
Engines 12 661.644.5370 | rotordoc1223@icloud.com
www.DuncanAviation.aero/parts/search
ALTHOUGH COMPOSITE DESIGN IS BECOMING MORE AND MORE APPARENT IN HELICOPTER DESIGN, MANY
LOAD CARRYING COMPONENTS OF HELICOPTERS ARE METALLIC. CONSIDERING THAT HELICOPTERS ARE
OFTEN OPERATED IN EXTREME CONDITIONS, CORROSION IS INDEED AN IMPORTANT TOPIC IN THE DOMAIN
OF HELICOPTER MAINTENANCE. IN THIS FEATURE, WE HAVE REACHED OUT TO INDUSTRY EXPERTS TO
ASSESS THE PECULIARITIES AND IMPACT OF CORROSION ON HELICOPTERS, THE PARTS OF HELICOPTERS
THAT ARE MOST EXPOSED TO CORROSION, AND THE TECHNIQUES AND TECHNOLOGIES AVAILABLE TO
MANAGE CORROSION.
PECULIARITIES AND IMPACT how an aircraft will perform under adverse operating
The complexity of helicopter design makes for intricate conditions,” he says. “Helicopters can also operate in
structures which are not always easily accessible, and environmental conditions which promote corrosion,
this leads to a volume of work required to gain access also adding additional burden to the maintenance
for inspection, points out Lee Holland director of regime due to the need for constant cleaning,
airworthiness at Bristow. “The selected materials and monitoring, and application of preventative measures.”
the corrosion prevention process plays a big role in
The demanding and intricate inspection regimes degrading the performance of helicopter turboshaft
required through to the preventative and restorative engines,” the company says.
process applied during maintenance are time Failure to adequately protect turbine engines
consuming, observes Holland. “There is also a need to from daily and long-term salt ingestion can lead to
collect data from inspection findings and repairs and an array of serious operational challenges, according
feed this information to allow operational experience to Donaldson Aerospace. “Among these there is
to drive change in corrosion control measures,” he decreased mission capability with limited hover time
affirms. over saltwater, engine component corrosion exposure,
The preventative and repair activities range from negative power trending reduction due to salt-related
simple treatments to areas found to be affected by engine maintenance, aggressive daily engine wash
minor corrosion problems, to the replacement of major regime required, increased engine overhaul cost, and
components when the corrosion is stress related or is programmatic operational costs,” the company says.
found deep within the aircraft structure during major According to Holland, structural areas of helicopters
maintenance activities, highlights Holland. “As a fleet that are most vulnerable to corrosion include the
ages, corrosion can be a major cause of lost revenue external fuselage, external fuselage high load paths
due to unavailability. If corrosion is left undetected or (smoking rivets), access doors rims, landing gear bays
untreated, it could lead to stress cracks in load path and jacking points, the cabin and baggage compartment
carrying structural components, restrictions in flight floor, the tail boom and fuselage internal bottom area,
controls and nuisance defects in electrical and avionics and the tail drive shaft area. “With regard to flight
systems,” he says. “These issues are considered in controls, corrosion vulnerable areas include bell cranks
maintenance programming and contribute toward the (interface areas with retaining hardware, bearings),
high frequency of maintenance interventions all are rod ends or rod interface areas. In the landing gear,
familiar with.” corrosion criticalities can be found in connecting
hardware, bushings, wheel rims, brake disks or pads
EXPOSED PARTS hardware, and in spherical bearings. Lastly, in electrical
From an operational standpoint, the causes and sources and avionics systems, corrosion can be found in
of corrosion may relate to maintenance or neglect (e.g., connectors and equipment mountings (e.g., antennas,
improper repairs and poor corrosion control programs lights, line replaceable units),” he says.
and training), the operational environment (tropical
or salt laden, humidity, etc.), accidental contamination TECHNIQUES AND TECHNOLOGIES
(chemical spills, human fluids, etc.), or to finish Corrosion prevention starts with the basic corrosion
deterioration (chipping, scratches, abrasion), affirms treatments applied to the aircraft and components
Holland. during manufacturing, affirms Holland. “Basic
Indeed, helicopters routinely contend with dust, corrosion protection applied to materials in chemical
sand, and debris that attack turbine engines thereby form, the application of primers and jointing
impacting engine reliability and hampering efficient compounds, and the application of corrosion
engine operation, affirms Donaldson Aerospace. “For preventative compounds all play an important role,”
missions over oceans or near coastal regions, tests show he says. “During maintenance, the goal is to detect
that inlet barrier filters (IBF) are able to significantly entropy and restore these treatments as they deteriorate
reduce airborne salts from entering the turbine and with the age and use of the aircraft. The use of visual,
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QUESTION — DO YOU KNOW WHAT YOUR TURBINE ENGINE IS SNACKING ON DURING WORKING HOURS?
JUNK FOOD — THAT’S WHAT! INTERMINGLED IN THE AMBIENT INTAKE-AIR AND VIA THE COMPRESSOR INLET,
YOUR TURBINE ENGINE IS CONSUMING, COMPRESSING, AND EXTRACTING ENERGY FROM MOUTHFULS OF
CORROSIVE AND EROSIVE AIRBORNE CLING-ONS! THESE AERIAL RESIDENTS ARE AN ENSEMBLE OF SULFUR
DIOXIDE, NITROGEN OXIDE, SMOG, BENZENE, METHANE, FINE SAND AND GRIT PARTICULATE, ASH. A VERY
UNHEALTHY AND COSTLY AIRBORNE SNACK FOOD THAT LEADS TO THE ENGINE’S EARLY PART 145 VISIT!
Let’s review our turbine engine’s activity. consider, that air, while a rather important component
Without hesitation, passing through and exiting the in the sustenance of all terrestrial life and deeds, is
compressor, the now compressed and concentrated, basically inert. Beyond the passive act of our breathing,
airborne chemical cuisine moves to the combustion air is an unwilling participant in the support of
section which energizes the inbound air with a any activity. And this fact is particularly apparent in
kerosene-based superheated brew of turbine fuel helicopter flight. Flying a helicopter, unlike breathing,
consisting of corrosive hydrocarbon compounds is not a passive occupation. Thus, when forced to
(paraffins, cycloparaffins or naphthenes, aromatics, and participate in the pursuit of sustained helicopter
olefins). And by “superheated” I mean the tip of the flight, air will extract a physical toll upon the airframe,
combustion section flame averages 3,000 degrees F dynamic components and particularly the gas path of
(1649 degrees C). At this point, while moving from the turbine engine. And this behavior is delivered by
combustion to turbine section and looking for the means of air movement or flow, and resident, airborne,
nearest exit, the energized air expands. Flowing close chemical cling-ons supplying two forms of turbine
to Mach speed the hot air, loaded with energy, erosive engine abuse — erosion and corrosion.
and corrosive elements, enthusiastically impacts the So, what say we examine these two naturally
airfoils of the turbine wheels, exchanging and depleting occurring, dynamic forces and see how they work
its speed, and heat energy for kinetic energy. This in harmony to affect the health of our helicopter.
application of thermodynamics causes the wheel / After which we will then discuss what we can do as
airfoil assembly to react mechanically and rotate as technicians to reduce the pace of their endeavor.
the exhausted air exits the engine. The now reactive
mechanical motion of the turbine wheels converts EROSION
to usable shaft power to and for the dynamic flight Erosion is “the slow, steady destruction or diminution
components to produce flight. With the engine power of something by wind, water, or other natural agents.”
section (compressor and turbine) processing 3.5 lbs A great example of erosion is evidenced by its effect
of air per second and operating at Revolutions Per upon an airfoil. To understand this better, let’s examine
Minute ranging from 50,000 (N1/Ng speed at 100%) the theory of lift as presented by Dr. Daniel Bernoulli.
to 30,000 (N2 / PT speed at 100%) keeping a constant And yes, I know there is a competing theory out there
6016 power output shaft speed driving the main rotor espoused by Sir Isaac Newton, but for this discussion
gearbox. we will work with Dr. Dan’s theory. Air flows over and
Because there is no escaping the toxins suspended in under the airfoil, wing / rotor blade. The airfoil shape
the air in which we exist, fly, and manipulate, to power causes the flowing streamline of air to separate at the
our flight, the preceding takes place each time our pilot leading edge and reunites at the trailing edge — this
exercises his or her flight skills. At an altitude of 1,000 causes lift. Why? Because of a couple of unbreakable
ft AGL, it makes you appreciate the robust competence physics laws. The upper and lower streamline must
of the modern turbine engine. Also, something else to reunite at the same moment at the trailing edge of the
TAKE ACTION
• First you get the flow action
of the water moving across
the engine gas path parts
“washing” as it flows. WHEN YOU NEED
M250 ENGINE & MODULE
• Next you have the pure
water performing as
a HAZMAT magnet,
attracting, and holding OVERHAUL AND REPAIR
onto the corrosive causing
elements it finds on its
journey through the engine
during the cleaning process.
Now that you understand the
why, how and what of turbine
engine hygiene, let’s discuss
the when. Think of it like your
own oral hygiene — AKA,
brushing your teeth. Brushing
your teeth should be the last
activity before bed-time — this
way all the Cling-Ons you have
accumulated on your teeth,
especially that last chocolate chip FAA & EASA CERTIFIED OVERHAUL
cookie, will not get the chance FOR RR 250 SERIES ENGINES
to attack, corrode and promote
NOW CERTIFIED TO OVERHAUL RR250-B17 ENGINES
tooth decay, as well as preventing
a lecture from your dentist. If
you think of this comparison
while waiting for your engine to
cool down after that last flight it
will make the job a little more
palatable. And have a couple of
chocolate chip cookies while
you wait, after all you will be
brushing your teeth later.
10570 Olympic Drive, Dallas, TX 75220
Mike Broderick has been an A&P
Technician since 1971. During his 214.351.1284 | 800.909.7616 | mary@actionaircraft.com
career he has worked as a shop and SALES CONTACTS:
hangar technician, field tech and Kevin Peterson – 775.857.9535 | Renee Bellrose Cootz – 503.858.0869
ACTIONAIRCRAFT.COM
operators were electronic news gathering, helicopter from being home every night to working 7-7, 14-14
air ambulance, offshore oil support, airborne law or 28-28 living in austere conditions — a common
enforcement, harbor pilot support, helicopter tourism house or hotel rooms with per diem. Being away from
and scientific research. Each of those activities had family is a factor to consider. In some operations you
its unique requirements that kept the jobs interesting will be required to be on call 24/7 and getting time off
and me on my toes! There are many more I did not can be challenging. Many also require the maintenance
have an opportunity to be involved with. I believe 135 to be carried out overnight so the helicopter can be
operations are the niche most helicopter A&P’s spend available for daylight missions. Pay seems to depend
their careers in due to the sheer diversity of activity and on the operations and geography and varies greatly
the number of operators. Schedules can vary greatly with experience as well. Work/life balance is entirely
up to the tech and choice of
residence is not limited to work
location. The thing is there is
Fly.
The first government
contractor I was hired by
had a contract to support the
Department of Homeland
Repeat.
FAA CRS under FAR part
145. U.S. Customs however
operated their aircraft under
FAR part 91. This was also my
first experience with a Labor
Union. I was an inspector for
Helicopter Turbine Rinse Systems the CRS based on my previous
position after being promoted.
1.800.863.9343 Customs operated the aircraft
much the same as any private
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TurboPureWater.com
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ISO 9001 + AS9100
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John Fraser, general manager of KTS. “This award This modification was developed for the H215/
recognizes our employees’ commitment to continuous AS332 L1e equipped with the Airbus Advanced
improvement and dedication to always providing Helicopter Cockpit Avionics System (AHCAS),
world-class service excellence each and every day. I’m electronic flight instrument system (EFIS) system and
proud to share this award with them.” CMA-9000 flight management system (FMS). Heli-
For more information, visit www.precisionaviationgroup.com. One is also working to develop a similar modification
for the AS365. This modification elevates the capability
of the helicopter through precision performance,
HELI-ONE RECEIVES STC APPROVAL FOR RNP
improved situational awareness, and enhanced safety.
MODIFICATION FOR H215/AS332 L1E The modification upgrade also gives the customer
Heli-One, a provider of helicopter maintenance, repair added long-term value to their aircraft by eliminating
and overhaul (MRO) services, receives EASA supple- the future issue of ILS obsolescence proactively.
mental type certificate (STC) approval for its required “This STC expands the excellent work done by our
navigation performance (RNP) approach modification team in continuing to progress the operational capability
for the Airbus H215 helicopter. The modification adds of this aircraft type, brings more value to the customer,
RNP approach capability down to localiser perfor- and provides the pilots with more tools to complete
mance with vertical guidance (LPV) minima, which re- their missions safely,” says Carolyn Forsyth, general
solves future obsolescence issues for instrument landing manager of Sales, Commercial and Customer Support.
systems (ILS) and enhances situational awareness.
The STC is part of a long-term modifications Does your company have news it would like to share
and harmonization project for an Airbus Super with Helicopter Maintenance magazine readers?
Puma variant fleet operator. Heli-One has extensive Email editorial director Joe Escobar at jescobar@
experience supporting the Super Puma helicopter helicoptermaintenancemagazine.com for consideration.
variant and has developed dozens of major and
hundreds of minor modifications for the versatile and
adaptable aircraft type.
HTIGLOBAL.US | 1.817.301.2659
pablolinares@htiglobal.us
April | May 2023 HelicopterMaintenanceMagazine.com 29
TRADE SHOW ETIQUETTE
The Spring trade show season is upon us. This was the first day of the show, and all three
The Helicopter Maintenance team was in Atlanta of them were sitting at their table in the back
March 7-9 attending HAI Heli-Expo 2023. of their booth working on their laptops and
It was nice walking the show talking to the talking with each other. We found out that their
exhibitors and learning about all the new boss had assigned them with a huge project.
products and services available for helicopter The boss insisted that they complete it by
maintenance professionals. Thank you to all Thursday (which was the last day of the show).
of you who stopped by our booth to say hi. For the first two days of the show, they came to
It was great meeting new people as well as the show and went straight to table in the back
catching up with longtime acquaintances. of the booth — where they sat all day trying
After the first day of the show, we went back to work together to finish the project. They
to our Airbnb to relax before heading out to didn’t even show up on the last day. Think of
dinner. Our publisher Greg Napert shared a all the money the boss spent getting the three
story with us. He had stopped by an exhibitor’s of them to the show — plane tickets, the cost
booth to say hi to an old friend. That person of the booth, hotel, and food costs. The boss
was on the phone, so he continued to walk the basically wasted all that money by asking them
aisles to visit nearby exhibitors. He checked their to complete a project that should have been
booth every now and then. More than an hour done at the home office — not on the exhibit
had passed, and his friend was still in the back floor of a trade show!
of the booth on the phone. Greg finally gave up It’s expensive to go to a trade show. Let’s
and decided to try to stop by the next day. make every effort possible to do what we have
Communication is an important of our jobs. been tasked to do! If you are at a trade show
We talk to our peers, supervisors, employees talking on the phone or working on your
and customers. When we are asked to attend laptop, you might as well just go home.
a trade show, our goal is to communicate One last pet peeve of mine regarding
JOE ESCOBAR with our customers, potential customers, and trade shows. I find it crazy that some people
colleagues. Sitting in the back of the booth believe they MUST answer their cell phones
talking on the phone is at the very bottom of immediately. If you are at a technical session or
things we should be doing at a trade show. professional development class, be courteous
On the last day of Heli-Expo I walked by and at least silence your phone. Better yet
a booth and noticed all the employees were — turn it off.You can always get back to the
sitting on a couch at the back of their 20x20 person when the session or class is over. And,
booth. They weren’t even trying to engage for crying out loud — never answer your
with the attendees passing by their booth.Yes phone when nature has called, and you are in
— the last day of the show is typically much the restroom! For some reason, some people
slower than the first two days. Nonetheless, answer their phone when they are sitting on
those employees were kicking back relaxing the throne. Worse yet, I even heard someone
on their couch talking to each other instead of place a call from the bathroom stall — and he
trying to engage with the attendees walking did it on speakerphone! Needless to say, there
right by their booth! were lots of urinals and toilets flushing while
Sometimes the responsibility of bad booth he was talking.
etiquette is the fault of a company owner or The Helicopter Maintenance magazine team
manager. For example, we were exhibiting at an will be at MRO Americas in Atlanta April 18-
NBAA-BACE conference a few years ago. As 20 and at the NBAA Maintenance Conference
the show started, we met the guys at the booth in Hartford, CT May 2-4. Hopefully we can
next to us. Not even an hour into the show, talk to some of you at one of the shows (just
one of the guys went to the table in the back of not in the restroom!).
their booth and started working on his laptop. Thanks for reading, and we appreciate your
Then one of the other guys joined him. Shortly feedback! – Joe
thereafter, the third guy sat down with them.
HCARE
IS
MISSION
LIKE NO
OTHER