Professional Documents
Culture Documents
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Cessna Single Engine Airplanes
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Cessna Single Engine Airplanes
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General Aviation
Sixty percent of active
single engines are Cessna
airplanes
5
Single Engine Safety Initiative
Why Inspect?
à Corrosion ((rust)) and metal fatigue
g are inevitable
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Visual Inspections
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Visual Inspections
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Visual Inspections
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Visual Inspections
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Single Engine Safety Initiative
Crack
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What is Corrosion?
Pure aluminum is
à Highly resistant to corrosion
à Too soft to be used as a structural material
Thus airframes are made of various high-strength
g g
aluminum alloys
à The most common aluminum alloy used in airframes is
“2024”
à "2024“ is composed of 95% aluminum, 4% copper, and
small amounts of manganese and molybdenum
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What is Corrosion?
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Corrosion Prevention
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Corrosion Prevention
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Corrosion Prevention
Cladding
à 2024 sheet can be coated ("clad")
( clad ) with very thin
layers (.001”) of pure aluminum to protect from
corrosion
pThe resulting material is known as "2024-T3 Alclad"
à The sheet material is vulnerable when the cladding
i compromised
is i d
pAt edges, drilled rivet holes, or if it is scratched
pMost
Most airframe corrosion occurs at seams and joints,joints which
is why cladding alone is not sufficient
pAdditional steps are necessary to protect seams, holes,
and un
un-clad
clad parts from exposure to electrolytes
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Corrosion Prevention
Chemical Treatments
à Alodine or other chemical treatments are used to
enhance the corrosion resistance of the pure aluminum
cladding
Sealants
à Paint is the most commonly used sealant for corrosion
protection
pModern polyurethane aircraft paints create a thick,
impenetrable barrier that effectively keeps moisture away
from the metal, and lasts a long time -- 10 years or more
pA good paint job is the best defense against airframe
corrosion
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Corrosion Prevention
Sealants
à Paint only protects the exterior of the airframe
à It is difficult to paint the inside of an airframe once it is all
riveted together
à The airframe interior of most pre-1986 airframes were
not painted (primed)
Corrosion Preventive Compounds (CPCs)
à Effective means for protecting those parts of an airframe
that were not originally protected from corrosion
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Corrosion Prevention
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Corrosion Prevention
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Results of Corrosion
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Corrosion Examples
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Cabin Interior – All Models
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Cabin Interior – All Models
Corrosion
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Models 177/210 Cantilever Carry-Thru
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Models 177/210 Cantilever Carry-Thru
Carry-Thru Beam
Corrosion
Corrosion
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Models 177/210 Cantilever Carry-Thru
Corrosion
Corrosion
Corrosion Pitting
g
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Models 177/210 Cantilever Wing Attach
Primary load carrying member
Corrosion is common on the carry-thru
y lugs
g and
the wing attach fittings
à Tight fitting faces act as a moisture trap
Made of 2014-T6 material
à High strength material but very susceptible to corrosion
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Models 177/210 Cantilever Wing Attach
C
Corrosion
i Pitti
Pitting
Carry-Thru Spar Lug
Corrosion Pitting
Wing Attach Fitting
Corrosion Pitting
Wing Attach Fitting
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Model 200 Series Elevators
Foam filled trim tab and foam filled trailing edge
à Absorbs moisture
pResults in corrosion
pChanges elevator balance
à When trim tab skin thins due to corrosion
corrosion, the actuator
can pull the fasteners through skin and disconnect
à Not repairable
p
à Inspect for pinholes, surface roughness, bubbling
à FAA SAIB CE-05-27R1 recommends replacement of tab
and trailing edges with non foam filled parts
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Model 200 Series Elevators
C
Corrosion
i
Hole caused
byy corrosion
Crack
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Main Landing Gear
Made from 6150M
High-Strength Steel
A pit as small as .005”
can initiate a fatigue
crackk which
hi h will
ill result
lt
in fracture of the gear
Keep
K surface
f painted
i t d
with polyurethane Rust
paint and blend out
pits per Service Model 182 Flat Spring Gear
Manual
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Main Landing Gear
.017” Pit
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Strut Braced Wing Front Spar
Wing spar made
from several sheets
of 2024-T3
aluminum clad
riveted together
Strut attaches at
wing splice joint
Corrosion observed
in underlying
sheets
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Strut Braced Wing Front Spar
Corrosion is often indicated by the discovery of a
missing rivet
à If rivet is missing, corrosion is likely to be severe
Australia asks owners to remove leading edge
after
f 15 years, iinspect andd reassemble
bl with
i h primer
i
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Strut Braced Wing Front Spar
Front Spar
Doubler
Spar Splice
Source: CASA General Aviation Aircraft Corrosion
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Strut Braced Wing Front Spar
Front Spar
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Airframe Ribs
Corrosion
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What is Metal Fatigue?
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Metal Fatigue
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FAA Regulations
g Through
g the Years
e Accidents
1969
Wing Fatigue
Evaluation 1969
AC91-82 Fatigue
Instructions for Management
Continued Program 2008
Airworthiness 1980
Regula
Fatigue
g
Cessn
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How to Control Metal Fatigue
g
Primary questions to ask
Yes
When will Where will Can cracks be
Inspect
it crack? it crack? found early
enough?
h
No
Modify or Retire
Structure Before
Cracks Start
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How to Control Metal Fatigue
When will it crack?
S
Suppose 1000 identical
id ti l wing
i spars were ffatigue
ti
tested with the same loads
Assume the average wing spar breaks at 10,000 hrs
They won’t all break at the same time
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Action Required
250
umber Broken
200
150
Average
Nu
100
50
0
0 2500 5000 7500 10000 12500 15000 17500 20000
H
Hours
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How to Control Metal Fatigue
g
Primary questions to ask
Yes
When will Where will Can cracks be
Inspect
it crack? it crack? found early
enough?
h
No
1 Analysis
1. A l i
Modify or Retire
2. Testing Structure Before
Cracks Start
3. Field Experience
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Metal Fatigue Examples
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200 Series Horizontal Stabilizer Front Spar
Cracks in
Spar Web
Crack
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200 Series Horizontal Front Spar Attach
Crack
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200 Series Horizontal Stabilizer Trim
Actuator Brackets
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200 Series Aft Bulkhead
Crack
Cracked Carry-Thru
Center Lug
L g
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Inspection Program Details
Inspections
à Based on field history
à Reviewed by customer focus group
Inspection
p Details
à Corrosion prevention and control program
pDirected visual inspections for corrosion completed during
annual
à ~15-20 visual inspections to inspect for cracks
pBorescope and magnifying glass required to complete
inspections
à ~5 inspections based on existing service bulletins
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Inspection Program Details
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Single Engine NDI training program
Instruction
à Beginning Summer 2012 all but 40 hours of the training
program will
ill be available
a ailable online
à NCAT will travel to other locations including foreign
pp this p
countries to support program
g as required
q
à NCAT will provide equipment and commercially
available standards when training is completed at their
facilityy
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NDI Training Program
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Conclusion
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Conclusion
Report anomalies to the manufacturer customer
service
à Corrosion
à Cracks in major structural elements
à Suspect
S t repairs
i
Send pictures!!
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