The Duncan Download Blog: Business Aviation Advice & Observations

Corrosion doesn’t care what make/model aircraft you have or how many flight hours it sees. All it cares about is getting its start and hoping you are not paying attention.

Types of Corrosion

Over the past 60 years, Duncan Aviation has seen and repaired corrosion damage on nearly every make/model business aircraft that has ever flown. Here are some common types of corrosion.

Filiform Corrosion: Occurs under painted surfaces when the protective coating has been compromised. The corrosion extends out from the original corrosion pit causing degradation of the protective coating.

Galvanic Corrosion: An electrochemical action of two dissimilar metals in the presence of an electrolyte and an electron conductive path, causing corrosion. It can occur when dissimilar metals are in contact.

Surface Corrosion: Chemical or electrochemical attack on surface of metal. It is a general roughening, etching, or pitting of the surface of a metal.

These photos are evidence of severe neglect. At Duncan Aviation, we have seen issues like this on business aircraft left outside quite often and subjected to the salt air (ocean air) without regular preventive maintenance and inspections for corrosion. 

Paint only needs to crack once to allow oxygen and moisture to get underneath and deteriorate the surface protection. Typically, this occurs anywhere there is a seam on the fuselage, wing, empennage or flight control surface. Corrosion remains hidden by the painted surface, or has been touched up with paint over the surface, trapping the growing corrosion underneath.

These examples of airframe corrosion could occur anywhere on the aircraft that the metal is not protected.  If the anodizing, alodine, or other surface protection is missing in that area, then surface corrosion, galvanic, (dissimilar metal) corrosion, or other forms of corrosion can occur.

It is very important to maintain the surface protection, and to perform regular inspections of all areas to detect corrosion before it grows.

Doing exactly what customers want can be exciting, if a bit challenging. However, every time they have asked, we have answered in a big way.

During a pre-buy inspection, one of Suzanne Hawes, Senior Sales Representative for Completions and Modifications in Battle Creek, Michigan, customers told her he wanted the Falcon 900 cabin seating reconfigured from 14 seats to 17. He also wanted to drop the overall weight of the aircraft so the round-trip customer flights he was planning could be completed with no fuel stops.

The reconfiguration required an STC (Supplemental Type Certificate), and Suzanne says team members from Engineering, Airframe, and Interior met with her, Project Manager Rich Jones, and Designer Ken Reita almost daily to compare notes and ideas after the initial meeting with the customer, his wife, and his aviation department.

“We had spreadsheets that we updated regularly with the weight of every single item, including coffee containers and life rafts, on that aircraft. We even took out the carpet and weighed it!” says Suzanne. “We pored over that interior, coming up with savings, ounce by ounce.”

Were you aware an important Airworthiness Directive is coming due at the end of the year? How about how what could cause your transponder to reject the beacon signal from Air Traffic Control?

No? Then you haven't read the April issue of the Duncan Intelligence. 

April Duncan Intelligence

Corrosion Does Not Discriminate Corrosion doesn’t care what make/model business aircraft you have or how many flight hours it sees. All it cares about is getting its start and hoping you are not paying attention. TFE731 Engine Airworthiness Directive Compliance Coming Due in October 2017 To be eligible for any OEM warranty consideration, affected engines need to comply by October 1, 2017. Aircraft Compass System Alignment Formulae If you replace or change the magnetic compass or components on your aircraft’s compass system, it is appropriate to swing the compass to verify or align it to minimize errors. TDR-94/94D Common Failures: Transponder Off Frequency If the transponder on your business aircraft is off frequency, it could begin to reject the beacon from ATC. Flat Rate Exchanges Help To Avoid Over and Above Charges 0xygen masks are an accessory that we hope we never need. But if the cabin pressurization system fails and our altitude is above safe levels, we really want those masks to work correctly.   Duncan Aviation’s Kansas City Shop Upgrades Gulfstream G150 for ADS-B  Read more.   Duncan Aviation Main Facilities Currently Performing Global Pre-Purchase Evaluations Read more.

The Duncan Intelligence is a free, technical newsletter for business aircraft owners and operators. Written in-house by Duncan Aviation's technical representatives, each edition includes technical tips and advice on topics and trends in business aviation. It is a free, monthly e-mail subscription for aviation enthusiasts around the world.

Duncan Aviation estimates that roughly 6,000 of the business jets in its core customer base still need ADS-B. That paints a pretty urgent picture of the industry. However, when you consider that ADS-B affects ALL aircraft, it's an even more dramatic picture. The number of U.S.-based turbine aircraft that still need ADS-B is closer to 11,000 and the number of all U.S. aircraft that still need ADS-B is closer to 74,000.

Brian Redondo, Duncan Aviation's Ft. Lauderdale Satellite Shop Manager, explains why he is concerned about the shortage of qualified installation labor.

"During the RVSM mandate compliance phase, shops performing RVSM installations could hire technicians from other shops that were slow because their core customers were not affected by the mandate. That won't be possible with ADS-B because every installation shop will be performing these installations for many years to come. And honestly, there is already a shortage of skilled labor as it is."

Operators need to begin looking at their paths for compliance and schedule the work needed, and soon. This video will highlight some of the key figures about why you need to be thinking about your upgrade now.

Duncan Aviation set out once again to make its presence and services known to the larger helicopter world at the 2017 Heli Expo in Dallas, Texas.

Just like 2016, we were greeted with enthusiasm, professionalism, and curiosity. But two things stood out to Ken Hurd, Duncan Aviation Accessories Technician that made this year’s show different.

1. A Lot More People

“This year's show was promoted as bigger than ever, and the size of the crowds seems to confirm the show as one of the best attended.”

2. More People Recognized Duncan Aviation

“During the show we were more widely recognized as a company that supports rotor wing accessories and avionics. Attendees visited the Duncan Aviation booth and shared their ideas on how we could take advantage of our impeccable reputation and abilities in the business aviation industry to expand our presence in the helicopter industry.”

Although we have been Heli-Expo attendees for several years, 2017 is the second year we had a show booth with team members representing areas that often touch helicopters or helicopter components. These areas include component repair and overhaul, parts sales and exchange, as well as the Government and Military contracts.

“I didn't know Duncan Aviation worked on helicopter components” was heard over and over again during the show. While it is true Duncan Aviation’s history is firmly grounded in the fixed-wing industry, we have been working on helicopter avionics for decades and the business is growing. 

Read about Duncan Aviation in the 2017 HAI Insight Magazine

According to Karl Detweiler, Duncan Aviation Components Business Development Manager, several attendees and exhibitors were glad to see Duncan Aviation expanding into helicopter components. “They expressed the need to have more long-term stability in the available service shops. To them, Duncan Aviation represents stability and quality."

Since purposefully promoting the Duncan Aviation helicopter component business in 2016, the projected growth for 2017 has a positive outlook. In fact, by the end of Heli-Expo, every Duncan Aviation representative found new helicopter business for the company to add to its already expanding portfolio.

We will continue to work hard and continue to build our reputation into the helicopter industry.

Have you heard about the Honeywell HTF7500E Stator Vane Seal Inspection Program? How about the cause behind those intermittent software failures on your Avidyne EX-500 MFD? 

No? Then you haven't read the March issue of the Duncan Intelligence. 

 March Duncan Intelligence

Falcon 7X Flap Rigging Precautions  Caution is needed when rigging the flaps on a Dassaut Falcon 7X aircraft. ADS-B Solution for Bombardier Challenger 800/850 SE Aircraft  This was an industry-first installation in the United States and was performed in the customer’s hangar. Honeywell HTF7500E Stator Vane Seal Inspection Program  This inspection program is applicable to the HTF750E model engine. Why Is My Avidyne EX-500 MFD Experiencing Intermittent Software Failures?  Completing a proper shutdown every time will prevent this. Got a crack in your APU Exhaust Support? Don’t Replace It. Repair It.  Duncan Aviation has AWS D17.1 certified welders and inspectors on-site, all capable of welding all types of materials for aerospace applications. The NBAA Tech Committee Wants To Hear From You Progress can only be accomplished if we have regular interaction with and feedback from you, the Citation operator.

Get The Duncan Intelligence In Your In-box

The Duncan Intelligence is a free, technical newsletter for business aircraft owners and operators. Written in-house by Duncan Aviation's technical representatives, each edition includes technical tips and advice on topics and trends in business aviation. It is a free, monthly e-mail subscription for aviation enthusiasts around the world.

For the Honeywell HTF7000 series engine model, there are a number of Service Bulletins that have become hot items. These can be accomplished at our Turbine Engine services shop in Lincoln, Nebraska, or any one of our Engine Rapid Response locations across the United States.

SB AS907-76-9021

Issued on May 13, 2016, this SB addresses the possibility of water entering the ECUs (Electronic Control Unit) after the aircraft is parked in the rain for an extended length of time. This may lead to unscheduled maintenance and expenses, aircraft dispatch delays, Loss of Thrust Control (LOTC) events and the possibility for inflight shut downs.

This is a CAT 1 SAFETY SB meaning it may require urgent action and may be associated with an FAA AD (Airworthiness Directive). Compliance is recommended to be within 400 engine operating hours or 18 months from the date the SB was issued.

This SB is relevant to the following aircraft:

• Bombardier Challenger 300/350 (HTF 7000/HTF 7350)
• Gulfstream G280 (HTF 7250)
• Embraer Legacy 450/500 (HTF 7500)

SB AS907-72-9064

This SB was issued to address instances of corrosion and pitting found in the inner and outer bypass ducts and supports. This SB will inspect and evaluate the corrosion and pitting of the FWD and AFT Ducts as well as the Core Cowls. If corrosion is noted, we will perform a repair to add a coat of paint as a preventive barrier for future contamination.

Because this SB requires the removal of the forward and aft outer fan bypass duct(s) and mid and aft inner fan duct panels, it should be scheduled during a maintenance event that will have the aircraft down for 7 to 10 days. I recommend accomplishing SB AS907-72-9044 at the same time, if applicable and you meet the required interval per the bulletin. Another good time to schedule this bulletin is during a 4000 hour digital borescope inspection. If repairs are noted from the borescope, most of these ducts and panels would be removed for the repair of the hot section components.

The SB applies to the following engines:

• AS907-1-1A (Bombardier Challenger 300)
• AS907-2-1G (Gulfstream G280)
• AS907-2-1A (Bombardier Challenger 350)

SB AS907-72-9044

The SB replaces the engine combustion chamber assembly. I recommend you have this SB accomplished at the same time as the previous SB mentioned (SB AS907-72-9064), if applicable and you meet the required interval per the bulletin. Most of the same panels and ducts need to be removed for both.

SB AS907-76-9013 W5

This SB changes the location of the W5 & OSSD (Overspeed Shutoff Detector) wire harness to increase its reliability and prevent failure in the high-heat environment in the engine.

Honeywell Engine Technical Support

Shawn Schmitz

Engine Technical Representative

+1.402.479.8166 office

+1.402.730.8767 mobile

Shawn.Schmitz@DuncanAviation.com

Every day we field questions from operators about the FAA’s NextGen initiatives. This tells us there is still significant confusion about the various acronyms associated with NextGen. 

What You Need to Know About the ADS-B Mandate

Here are some of the more common questions surrounding the many acronyms and which acronym applies to which solution.

ADS-B (Automatic Dependent Surveillance-Broadcast). A cooperative system that transmits digital information regarding the identity, velocity and position of the aircraft to ATC (Air Traffic Control). This is a mandated item. Every aircraft planning on flying in controlled airspace after December 31, 2019, will need to have ADS-B Out. To comply with the ADS-B Out mandate, aircraft need a 1090-MHz Mode S extended squitter transponder combined with a certified GPS (Global Positioning System) navigation source such as WAAS GPS. ADS-B In allows the aircraft to read ADS-B signals from other aircraft.

WAAS (Wide Area Augmentation System). A system developed to augment GPS with the goal of improving its accuracy, integrity and availability. Intended to correct GPS signal errors, WAAS collects data from ground stations and satellites, allowing aircraft to rely on GPS for all phases of flight, from takeoff through Category I precision approaches. WAAS permits the use of more fuel efficient flight planning and approaches that have reduced minimums. WAAS-approved units also incorporate navigation procedures to take advantage of preferential flight routing. To upgrade to WAAS, certified equipment appropriate for the aircraft must be installed and properly approved by the FAA or its designee.

FANS 1/A– (Future Area Navigation Systems). This is a datalink system that lets pilots and ATC communicate directly using text transmissions that appear on the CDU (Central Control Unit). It requires a certain level of navigational performance that your aircraft must meet in order to fly overseas while communicating with ATC via CPDLC.

CPDLC (Controller Pilot Data Link Communications.) This is the method of communications being used for operators flying overseas outside of VHF coverage. The aircraft must meet a certain level of precision and performance to fly in these assigned flight routes. CPDLC is the text-messaging component of FANS 1/A.

Still have questions?

• Contact the Duncan Aviation Satellite Shop (www.DuncanAviation.aero/locations/#satellites) nearest you,
• Call any one of our Duncan Aviation Avionics Installation Team Members (www.DuncanAviation.aero/services/avionics-installation/contacts), or call +1 402.475.2611 for more information.
• Visit the Duncan Aviation ADS-B web page at: www.DuncanAviation.aero/adsb
• Download our Straight Talk booklets: www.DuncanAviation.aero/resources/straight-talk

Thank you for helping us celebrate 60 years of providing service to business aviation. We are proud of our family ownership and history of excellence, innovation and responsiveness. we are also truly grateful to have had the opportunity to work with you. We wish you a season of joy and the very best for 2017 and beyond.

It is Duncan Aviation’s 60th year of helping business aircraft operators be safe, efficient and productive. For six decades, customers have asked us for solutions and services. We are celebrating our 60 years by telling the stories about the people of Duncan Aviation who listened and took action.

Celebrate with us by subscribing to the Duncan Download blog, following us on Facebook and Twitter (@DuncanAviation) and visiting our anniversary website at www.DuncanAviation.aero/60.