October 25, 2023 - No. 044

In This Issue 

: New CFM56 Blades Promise Increased Durability

: Top-Tier Supplier Performance Source Of Airline, MRO Frustration

: Pratt & Whitney engine issues impact multiple airlines 

: TEXTRON AVIATION BRINGS PEACE-OF-MIND TECHNOLOGY TO THE BEECHCRAFT DENALI COCKPIT

: Rolls-Royce plans up to 2,500 job cuts to revamp its ‘burning platform’ business

: Hartzell Bought By Equity Firm

: Microturbine Set For Certification Tests

: Spirit AeroSystems, Boeing Reach Agreement to Support Production Stability

: More on Lycoming’s XR-7755 engine 

: Blackhawk Completes 150th Caravan Engine Upgrade

: Passenger Shares Photo Of Their Plane – And The Cockpit Is “Duct Taped” On


 


New CFM56 Blades Promise Increased Durability
Sean Broderick 
October 19, 2023
The new HPT blade.
Credit: GE Aerospace

CFM International is rolling out an upgraded CFM56 high-pressure turbine (HPT) blade that the company expects to improve durability in a fleet that still has years of overhauls and service life ahead.
 
The new blades, which can be installed on all CFM56-5B and -7B versions, include increased wall thickness and an optimized dovetail design to minimize stress, while maintaining fuel-burn improvements introduced with the Tech Insertion blade lines brought out in 2007.
 
Operators will have ample opportunity to benefit from the new blades. Almost half of the 24,000 CFM56s in service have yet to see the first of what will likely be at least three shop visits in their service lives.
 
“Many of our customers are transitioning their narrowbody fleets, and the new CFM56 HPT blade can help them to extend time on-wing to optimize cost of ownership and enhance the residual value of their engines," said Jacey Welsh, GE Aerospace's executive vice president for the CFM56. "We are also providing attractive upgrade options to customers operating older CFM56 configurations.”
 
CFM56 shop visits topped 2,000 annually in the years leading into the 2020 downturn. Safran, a 50-50 partner in CFM with GE Aerospace, said in July that worldwide shop visits were on pace to hit 2,000 in 2023.
 
Delays with new deliveries have helped drive demand for older narrowbodies, including Airbus A320s and Boeing 737 Next Generation models powered by CFM56s. That should help shop visits climb for several more years before settling into an annual level of about 2,000 per year.
 
“We continue to invest in both product and support upgrades for this fleet," said Jérôme Morhet, CFM executive vice president at Safran Aircraft Engines. "With the introduction of the new HPT blade, we are focused on building inventory to support our customers’ future shop visits.”
 
The blades are being produced at GE Aerospace's plant in Greenville, South Carolina.


 


 

 


Top-Tier Supplier Performance Source Of Airline, MRO Frustration
Sean Broderick 
October 17, 2023

AMSTERDAM—Nagging gaps in commercial aviation’s largest supply chain links are frustrating airlines and aftermarket service providers that have few good options for minimizing the resulting disruptions.

“Three years have passed, and we’re still speaking about capacity constraints,” said Iván González Vallejo, Iberia Maintenance director of supply chain and MRO strategy. “We can’t be expected to just raise our inventories. OEMs need to ramp up capacity. Not just parts volume, but also adding diversity in their sourcing.”

Vallejo, speaking on an MRO Europe panel here, joined several other airline and MRO executives in expressing frustration at an apparent lack of commitment from major manufacturers to address supply issues.

In some cases, parts are in short supply. In others, raw materials needed for repairs are not available.

Vallejo cited CFM International CFM56-7B overhaul work Iberia has just begun for Air Europa. Two of the first three engines inducted are sitting idle, waiting for honeycomb needed for low-pressure turbine liner repairs. The wait will push the turnaround times for the engines to about 90 days, or 30 more than Iberia’s target.

Ben Moreau, SVP Strategy and Business Development for AFI KLM E&M, has detected a similar, disturbing pattern. An examination of recent component orders in a specific segment found that the average performance for the top 10 vendors had parts coming 90 days later than promised. The worst performer is 240 days behind.
“We have a problem there,” Moreau said. “OEMs need to invest more to solve that situation. They have a huge responsibility.”

He called the problem a symptom of “a long-term business model” that has OEMs keeping a tight grip on intellectual property. Airlines and maintenance shops struggle to get information needed to develop repairs, and OEMs shun options such as using parts manufacturer approval suppliers as backup suppliers or sources for parts on sunsetting platforms.

“We are currently facing a situation where the industry has been built with so many limitations that when there is a shortage in the supply chain, there is less agility to adjust,” Moreau said.

One result is harmful strategies, such as airlines or shops stockpiling additional parts as insurance, that can exacerbate shortages. Another inevitable outcome is higher costs passed down the supply chain.

Air Europa Chief Technical Officer Pedro Macías Domínguez said the airline’s repair expenses have gone up 20% with no related benefits. Materials and work simply cost more and takes longer, and the airline is expected to deal with it.

“We need to share the pain,” he said. “Twenty years ago, that collaboration was there. It wasn’t easy, but it was there. I don’t see that now.”

Airbus head of flight hour services Daniela Serafini agreed that the landscape must shift. “We have learned a lot. We all have to be ready and be able to react quickly,” she said. “I think anticipation is the key word. When we see something happening, we need to find a solution much faster than in the past.”

Top-Tier Supplier Performance Source Of Airline, MRO Frustration
 

Pratt & Whitney engine issues impact multiple airlines 
15.09.2023 - 03:35 UTC

Wizz Air Holdings is one of several airline groups grappling with significant numbers of A320neo Family-type aircraft going out of service for an extended period after RTX Corporation, owner of Pratt & Whitney, told customer airlines earlier this week that approximately 3,000 geared turbofan (GTF) engines fitted to in-service aircraft will need to be inspected.

In an advisory published on September 11, RTX expanded the number of PW1100 GTF engines needing inspection. The engines are used on A320neo family-type aircraft. When it first disclosed the metal contamination issue in the Pratt & Whitney-manufactured engines in late July, RTX estimated around 1,200 motors would require inspection. That number has now grown to approximately 3,000, or over 90% of the 3,200 GTF engines presently in service.

The engine inspections, which may take as long as 60 days, will take place between 2023 and 2026 and result in around 350 aircraft being parked each annually through 2026, although RTX says that figure will peak at about 650 planes in the first half of 2024.

Pratt & Whitney engine issues impact multiple airlines

TEXTRON AVIATION BRINGS PEACE-OF-MIND TECHNOLOGY TO THE BEECHCRAFT DENALI COCKPIT
    
May 08, 2023

WICHITA, Kan.--(BUSINESS WIRE)-- With customer input at the forefront of its product investments, Textron Aviation today announced it is bringing the revolutionary Garmin Emergency Autoland system to its new clean-sheet design Beechcraft Denali single-engine turboprop. The new feature is being implemented into the aircraft’s development and flight test program and will be available as a standard feature at time of entry into service.

The Beechcraft Denali aircraft is designed and will be manufactured by Textron Aviation Inc., a Textron Inc. (NYSE:TXT) company.

The Garmin Emergency Autoland system is the world’s first certified system of its kind. It provides a means for the aircraft to land automatically in the unlikely event of pilot incapacitation. A passenger can activate the Emergency Autoland system by pressing a dedicated button in the cockpit. Once activated, the system immediately takes control of the aircraft and informs ATC of the emergency. It then calculates a flight path to the most suitable airport or runway, while avoiding terrain and adverse weather, initiates a stabilized approach and automatically lands the aircraft, bringing it to a stop before shutting down the engine.

“The Autoland system is an excellent addition to the Beechcraft Denali and the G3000 avionics suite, and we’ve included it in the program as a direct response to continued conversations with our customers,” said Lannie O’Bannion, senior vice president, Sales & Flight Operations. “The feature makes the Denali even more desirable to a wider audience as it adds yet another element of assurance and peace of mind for pilots and passengers.”

Textron Aviation is aligning the Beechcraft Denali aircraft certification timing, which is expected in 2025, to the certification timeline for the new Catalyst engine. The Denali is the first aircraft powered by the new, more efficient engine.

“We continue to experience great progress with the Denali development program, and we believe the aircraft will be a game changer in the single-engine, high-performance turboprop segment,” said Chris Hearne, senior vice president, Engineering. “Our customers are excited for the Emergency Autoland feature on the Denali and, while our goal is to achieve type certification as quickly as possible, it is of greatest importance to assure that every detail is completed with the highest quality.”
The Denali flight test certification program features three flight test articles. The three flight test aircraft have surpassed 1,300 flight hours.

About the Beechcraft Denali
Engineered to achieve cruise speeds of 285 knots and full fuel payload of 1,100 pounds, the Beechcraft Denali is designed to have a range of 1,600 nautical miles at high-speed cruise with one pilot and four passengers and will be able to fly from Los Angeles to Chicago, New York to Miami or London to Athens.
The Catalyst engine – a more efficient, FADEC-equipped, 1,300 shaft horsepower (SHP)-rated turboprop engine – eases pilot workload with its single-lever power and propeller control. Like the company’s other aircraft, the Denali can also use sustainable aviation fuel.

The airplane is also equipped with McCauley’s new 105-inch diameter composite, 5-blade, constant speed propeller, which is full feathering with reversible pitch and ice protection.

The cockpit features the Garmin G3000 intuitive avionics suite with high-resolution screens and touchscreen controllers. An integrated Garmin autothrottle interfaces with the Automatic Flight Control System (AFCS) and Flight Management System (FMS) provides easy speed control throughout all regimes of flight from takeoff to touchdown.

Class-leading passenger experience
The Beechcraft Denali’s flat-floor cabin is designed to be the largest in its segment and offers the versatility to easily convert between passenger and cargo configurations. The cabin features a standard seating configuration of six individual reclining seats and offers a nine-place high density seating option. Passengers will also enjoy large cabin windows, a forward refreshment cabinet and an in-flight accessible baggage compartment. An optional externally serviceable belted lavatory in the rear of the cabin is also available.

About Textron Aviation
We inspire the journey of flight. For more than 95 years, Textron Aviation Inc., a Textron Inc. company, has empowered our collective talent across the Beechcraft, Cessna and Hawker brands to design and deliver the best aviation experience for our customers. With a range that includes everything from business jets, turboprops, and high-performance pistons, to special mission, military trainer and defense products, Textron Aviation has the most versatile and comprehensive aviation product portfolio in the world and a workforce that has produced more than half of all general aviation aircraft worldwide. Customers in more than 170 countries rely on our legendary performance, reliability and versatility, along with our trusted global customer service network, for affordable and flexible flight. For more information, visit www.txtav.com| www.defense.txtav.com| www.scorpionjet.com.

About Textron Inc.
Media:
Rachel Williams
+1.316.706.7201
rawilliams@txtav.com


 


Rolls-Royce plans up to 2,500 job cuts to revamp its ‘burning platform’ business
HANNA ZIADY, CNN
October 17, 2023 at 6:18 AM

Aircraft engine maker Rolls-Royce will slash up to 2,500 jobs worldwide in a bid to streamline its operations and tackle years of underperformance.

Britain’s flagship engineering firm, which makes engines for Boeing (BA) and Airbus planes, said Tuesday that the cuts were part of a broader strategic overhaul to “remove duplication and deliver cost efficiencies.”

The restructure will lead to between 2,000 and 2,500 job losses from a global workforce of 42,000, a cut of around 6%. (Rolls-Royce is a separate company from Rolls-Royce Motor Cars, a wholly owned subsidiary of BMW. The two businesses bearing the Rolls-Royce name were part of the same firm until the 1970s.)
“We are building a Rolls-Royce that is fit for the future. That means a more streamlined and efficient organization that will deliver for our customers, partners and shareholders,” CEO Tufan Erginbilgic said in a statement.

A jet engine at the assembly line of the Rolls-Royce plant in Dahlewitz near Berlin, Germany - Nadja Wohlleben/Reuters

The revamp is the latest turnaround attempt by the company, which set out to cut at least 9,000 jobs during the Covid-19 pandemic when demand for air travel collapsed. And earlier, in 2018, the company planned to cut 4,600 positions to save costs.

Erginbilgic — who became chief executive in January after more than 20 years at oil giant BP — has been blunt in his assessment of the aerospace and defense firm’s performance. In an address to Rolls-Royce staff not long after taking the helm, he described the business as a “burning platform” that was falling behind key competitors and destroying value for shareholders.

“Rolls-Royce has been underperforming for an extended period,” he noted at the company’s annual shareholder meeting in May.

“Cash generation has been unsatisfactory, and our debt is still too high. Too much of our gross profit is simply covering our overheads and interest payments.”
Erginbilgic used the address to announce a “transformation program” that would create an “efficient business with a competitive cost base,” without detailing the impact on employees.

Under the plan unveiled Tuesday, staff working on product safety and engineering standards will be combined into a single team, and back-office functions, such as finance, legal and human resources, will also be brought together. The overhaul will see chief technology officer Grazia Vittadini leave the business in April 2024.
“This is another step on our multi-year transformation journey to build a high-performing, competitive, resilient and growing Rolls-Royce,” Erginbilgic said.
Investors cheered the changes, lifting the stock more than 2% in morning trade, though it later pared those gains. The stock has climbed more than 200% over the past year, making it the best performer in London’s FTSE 100, according to Victoria Scholar, head of investment at online investment platform Interactive Investor.

“Things couldn’t be going much better for Erginbilgic,” she said in a note Tuesday, pointing to the “sharp jump” in profit in the first half. “Its transformation plan is faring well, with improving operations, the post-pandemic rebound in international flying and increased defense spending.”


 


Hartzell Bought By Equity Firm
By Russ Niles
Published: October 16, 2023

Arcline Investment Management, an $8.9 billion private equity firm, has acquired Hartzell Aviation from Tailwind Technologies. The deal includes Hartzell’s two business units, the propeller business and Hartzell Engine Tech, which makes engine subsystems ranging from turbochargers to engine mounts. “Our family has been blessed to be the stewards of Hartzell Aviation for 37 years. As we look to the future, we believe Arcline fully embraces our core value – Built on Honor – and will bring the skills and resources to build on over a century of excellence and innovation,” said Jim Brown, president of Hartzell Aviation.

Arcline says it will honor the century-plus history of the storied propeller maker and embark on an unspecified growth plan. “As investors exclusively focused on Critical Suppliers to Critical Industries, Hartzell’s portfolio of flight-critical propeller and engine subsystems for a large and long-lived installed base fits perfectly with Arcline’s strategy. We are excited to partner with the Hartzell team to carry on its legacy generated over the past 100 years and facilitate the Company’s next phase of growth,” the company said in a statement.


 


Microturbine Set For Certification Tests
Guy Norris 
October 19, 2023
Credit: Brett Schauf/ShowNews

LAS VEGAS—A compact microturbine capable of generating 30 kW and weighing 150 lb. is undergoing certification for application as a power source for multiple applications including a general aviation auxiliary power unit or as a turbogenerator for advanced air mobility vehicles, and uncrewed aircraft systems.

Developed by Miami-based KW Micro Power, the gearless, oilless device measures 15 in. in width and is only 30 in. in length. Configured with single centrifugal compressor and turbine stages, the engine has an operating speed of 90,000 rpm and can run on Jet A, JP8 and diesel, says Enrique Enriquez, president of KW Micro Power. The unit’s ability to operate on diesel and Jet A makes it likely it will also run easily on sustainable aviation fuel, he adds.

Innovations include extensive use of foil-air bearings—a type of air bearing in which the shaft is supported by a compliant foil journal lining, as well as 3D-printed components with internal passageways for advanced heat exchanger capability. Fuel is passed through a hollow generator and inlet housing to provide cooling.
“Normally this housing would be running at about 300F, but the fuel brings the temperature down to about 86F. Before all that energy was dissipated into space but it's now in the fuel, which makes the whole cycle more efficient. We do something very similar with our combustor which picks up energy from the preheated air from a number of 3D-printed channels. It is free energy that nobody was using,” says Enriquez.

The unit, which is designed for simple maintenance with few parts, is electronically controlled and can be ganged together with sister units for higher power requirements, he adds. The device is also being evaluated for potential military applications including as a power source for direct energy weapons.


 

Spirit AeroSystems, Boeing Reach Agreement to Support Production Stability

NEWS PROVIDED BY
Spirit Aerosystems 
18 Oct, 2023, 07:30 ET
 
•	Memorandum of Agreement to enable production increases and enhance quality, predictability

WICHITA, Kan., Oct. 18, 2023 /PRNewswire/ -- Spirit AeroSystems, Holdings Inc. [NYSE: SPR] announced today that its subsidiary, Spirit AeroSystems Inc., entered into a Memorandum of Agreement (MoA) with The Boeing Company. The agreement enables greater collaboration to achieve improved quality and higher deliveries in the future. "Boeing and Spirit will continue to work shoulder to shoulder to mitigate today's operational challenges," said Spirit AeroSystems.

President and CEO Patrick M. Shanahan said: "Our collective teams will focus on further generating supply chain performance and resiliency. This united effort to synchronize our production systems will enable greater market responsiveness and delivery assurance."

The agreement strengthens the strategic relationship between Spirit and Boeing for the long-term to fulfill operational commitments and airline expectations. 
On the web: www.spiritaero.com
On Twitter: @SpiritAero


 


More on Lycoming’s XR-7755 engine
By Paul McBride 
October 15, 2023 


Note: See interesting photos in the original article.

When Joy Hobbs sent in a photo of her grandfather and his co-workers by Lycoming’s XR-7755-3 engine, it attracted a lot of comments from General Aviation News readers.

First of all, I’d like to thank those readers who submitted comments to the Letters to the Editor column regarding “The men who built the largest piston engine in the world” that Lycoming built in the mid 1940s.

Just to clarify: This was not the largest engine ever built as was pointed out by one of our readers. It was, however, the world’s largest aircraft engine ever built at that time.

The thing that has always amazed me is the fact that this massive engineering feat was done without computers, Cad/Cam systems, and the many other technical devices that are commonplace in our industry today.

This engineering design took place over a relatively short period of time — 1944 to 1946 — and was done using only good engineering practices and a slide rule.

The Lycoming XR-7755-3 on display at the National Air and Space Museum’s Steven F. Udvar-Hazy Center. (Photo by Sanjay Acharya via Wikipedia)

As I may have mentioned in the past, my dad was a member of the engineering group. As a draftsman, one of his jobs was to lay out the reduction gear assembly for the blueprints that would be made as a part of the assembly process.

I’m fortunate to have a copy of those blueprints, along with one of the intake valves used in the engine. Since most of you are familiar with the intake valves currently being used in today’s aircraft engines, I’m sure this photo will come as a shock.

The dimensions for this XR-7755 valve look like this: The valve stem is 6.5 inches long and the stem diameter is ¾ of an inch. The actual valve face measures 3-¼ inches across.

Each one of these intake valves weighed approximately 1.2 pounds. Taking that weight into consideration, it’s not difficult to understand why the dry weight of this monster engine was about 6,000 pounds.

As we know, this engine was initially designed for installation on the Convair B-36 bomber. It was a tremendously large aircraft that would have had six of these gigantic engines installed. I can’t even begin to estimate the total gross weight of the aircraft we’re looking at here.

The Convair XB-36 in flight. (U.S. Air Force photo)

If the XR-7755 weighed 6,000 pounds dry and we now add the engine oil (I never heard the total gallons), we’re looking at some pretty big numbers. Since the XR-7755 was a liquid-cooled engine, we’d also have to add the weight of the liquid coolant to the equation as well.

Again, I have never heard any weight figures for the coolant fluid, but I know to keep the engine temperature within its operating limits, the coolant pump had a capacity of providing 750 gallons per minute.

As I mentioned in some of my previous writings about this engine — and to give you some perspective of this capacity — you could nearly fill a standard railroad tank car in about 10 minutes. This 750 gpm capacity is very similar to present-day fire truck pumpers.

Just take a moment and think about this: This engine featured nine dual-lobe overhead camshafts, which shifted axially for takeoff and cruising efficiency, and a two-speed, geared, dual-rotation propeller drive.

When you stop and think about it, this was one heck of an undertaking for Lycoming and the people involved in the program. I consider myself so fortunate to have been able to work alongside some of these great team members during my time at Lycoming.

It’s too bad that these engines weren’t retained as an example of what could be accomplished during that time period in history. The sole surviving engine is on display at the National Air and Space Museum’s Steven F. Udvar-Hazy Center in Chantilly, Virginia.

I must say that while this exhibit is something to see, I wish the engine was actually mounted in a horizontal position rather than the present vertical configuration to give viewers a better perspective of how large this engine actually is. Its present display configuration may be due to space limitations, but regardless, if you ever get the chance to visit the facility, I can guarantee you’ll find it educational and informative.

Oh, one more thing before I close. My dad told me that there was a target date to complete various stages of this engine and if that date were met, the entire group would get a bonus amounting to one week’s pay.

Fortunately, my dad was in a group that met the date, and he was rewarded with one week’s pay for a total of $15!

Paul McBride, an expert on engines, retired after almost 40 years with Lycoming.


 


Blackhawk Completes 150th Caravan Engine Upgrade
Horsepower increase expands the Caravan’s scope of operations

By GREGORY POLEK • Senior Editor
October 16, 2023

Blackhawk Aerospace has completed its 150th Cessna Caravan engine upgrade. It offers two upgrade options for the turboprop single: the XP140 and the Vy conversions, which feature the Pratt & Whitney Canada PT6A-140 and the PT6A-42A engine, respectively.

“This is a major milestone in our Caravan program’s success,” said Blackhawk president and CEO Jim Allmon. “For these workhorse airframes, more power is a necessity for mission capability, and we’re honored to provide solutions that breathe new life into the fleet.”

Caravan operations span a variety of mission profiles, including cargo, corporate, passenger, and military applications. In each case, Blackhawk’s upgrades deliver a significant increase in available horsepower, improving climb rates, raising safety margins, and affording access to more destinations including those in hot and high conditions or with unimproved runways.

Guyana-based Blackhawk operator Air Services, which provides scheduled and charter operations, medevac flights, and sightseeing tours, placed an order for its eleventh XP140 upgrade.

“The additional available horsepower is crucial for our operations,” said Air Services' Bhesham Persaud. “It allows us to take off, climb, and cruise at levels we couldn’t before, which expands our versatility to safely operate in every corner of Guyana.”

Separately, Blackhawk Aerospace Technologies (BAT) has just received the Garmin Platinum Dealer Award, which places it at the highest level of Garmin dealer classification. As a top dealer, BAT can offer upgrades such as the King Air G1000 NXi package.

Pollard Aircraft and BAT have also partnered to perform six Garmin G1000 Autoland and autothrottle upgrades on King Airs that Pollard sells.


 


Passenger Shares Photo Of Their Plane – And The Cockpit Is “Duct Taped” On
by Gary Leff 
October 22, 2023

A reader shared a photo with me of a plane in Albuquerque on Friday with more speed tape on its front than I’ve ever seen in my life. The forward fuselage is the part of the aircraft’s body where the cockpit is located. It’s the plane’s “first impression” – and this one doesn’t make a very good one.

These sorts of images scare passengers. Customers see what looks like duct tape on a plane and get understandably concerned! But it is actually aluminum pressure-sensitive tape that can stick to an aircraft’s fuselage or wing at high speeds.

It is used in aviation for minor, temporary repairs on aircraft. It has high resistance to weather conditions and extreme temperatures. And its use is strictly regulated. In general, it is for temporary fixes until a more permanent repair can be made, often within a few days.
The location and nature of the damage on an aircraft determines whether use of speed tape is appropriate, consistent with FAA guidelines and the aircraft manufacturer’s structural repair manual. Speed tape is not indicated where it could potentially affect the structural integrity of the aircraft (or cause an aerodynamic issue).

So you’ll generally see it used for minor, non-structural damage such as covering minor dents or scratches that don’t affect structural integrity and securing loose objects such as a panel until they can be properly fixed.

There’s nothing wrong with this plane, in the sense that it’s perfectly airworthy. But every time passengers see something like this they’re shaken, and they worry about how well managed and maintained the airline they’re flying is.



Curt Lewis