p_Managing_ageing_aircraft__Solutions_for_ageing_fleets__Ageing_aircraft_support_(A320_Family).pdf

Airbus Customer Services Cécile DAUDET

Managing Aging Aircraft A320 Program Structures seminar 2015

Managing Aging Aircraft

Presentation title Expertise details Cécile started at Airbus in i n the Flight Fli ght Test Test Domain where she performed flight test envelop opening for A318, A340-500/-600 and A380. Then she moved to Structure Support Engineering in 2008, where she firstly dealt with A320/A380 fuselage and cockpit windows for all programs. Now she’s product leader of nose/forward fuselage and cockpit windows for all programs. She’s been deeply involved on A320 maintenance planning update since 2013.

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Presented by

Cécile DAUDET Product Leader  AT  A TA 53-10/53-20 and ATA 56 [email protected]

Managing Aging Aircraft

Presentation title Expertise details Cécile started at Airbus in i n the Flight Fli ght Test Test Domain where she performed flight test envelop opening for A318, A340-500/-600 and A380. Then she moved to Structure Support Engineering in 2008, where she firstly dealt with A320/A380 fuselage and cockpit windows for all programs. Now she’s product leader of nose/forward fuselage and cockpit windows for all programs. She’s been deeply involved on A320 maintenance planning update since 2013.

Your photo here

Presented by

Cécile DAUDET Product Leader  AT  A TA 53-10/53-20 and ATA 56 [email protected]

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Context 2007 Mandatory Fleet survey resulted in a new fatigue mission(*) 1FC=2FH

2008 New Full Scale Fatigue Test

April 2012 ALS(**) PART 2 revision 1 

 A320 Extended Service Goal Goal



 A320 Update due to new fatigue mission

(mission mix 34% 0.75hr + 49% 2hr +17% 4.5hr)

2014 A320 fleet leader reaches the Design Service Goal (DSG) (*) Initial certification mission 1FC=1.25FH

(**) Airworthiness Limitation Section

2015 Widespread Fatigue Damage (WFD) justification (FAR 26.21)

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update – Damage Tolerant Certification Initiation

The A320 Structure is certified as Damage Tolerant

Detectable

Critical

• Crack can occur Crack length

• Structure can still withstand significant loads without failure • Demonstrated Maintenance Programme published in the

 ALS(*) Part 2

Critical

Interval Safe Crack Growth Period

Detectable

FCdet

FC Mandated Threshold

FCcrit

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update - ALS Part 2 Revision 1 dated April 2012 / ISB Impact on ALS Part 2 Revision 1 A320-200 Tasks -

-

46 New with a Grace Period 98 Revised: - 16 Reduced threshold - 82 Increased threshold 71 Deleted Maintenance A320-200 global status 12% less tasks 13% Higher Mean Threshold 8% Higher Mean Interval In addition 19 ISBs have been introduced

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update - Major Inspections findings One operator had major findings on high Flight Cycle aircraft (~45.000FC) while performing the applicable inspection tasks: Frontal windshield frame, Lateral sliding window frame, Frame 16 (crossbeam splicing), Pressure membrane FR35-36, Centre wing box upper beam.

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update – Severity assessment Weight on severity index

Key Parameters

Threshold Re-inspection interval Finding rate Impact on planning Repair solution

Spares available

at initiation

1

with propagation

2

long

1

short

3

low

1

high

2

low

1

high

3

available

1

not available

3

yes

1

not yet

3

Severity Index Threshold x Interval x Finding rate x Impact planning x Repair solution x Spares availability

- Low - Medium - High

27 ALI/ISB identified as most critical tasks

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

 ALI/ISB – Section Nose Fuselage

ALI 531103 Door stop fittings FR20 TH 48 000 FC

ALI 531101 Door cut out intercostal fittings FR16/20 TH 36 500 FC

ALI 531127 FR11 splicing TH 42 400 FC

ALI 531110 Cross beam splicing FR16/20 TH 34 700 FC / 69 400 FH

ALI 531129 Frontal windshield frame TH 30 600FC

ALI 531184 Vertical web fwd pressure bulkhead TH 34 000 FC

ALI 531126 FR 8 splicing TH 25 500 FC

MRB 531125 Lateral sliding window frame TH 48 000 FC/ 96 000 FH  ALI 531133 TH 26 700FC  ALI 531105 TH 27 600 FC  ALI 531130 TH 48 000 FC

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage  ALI 531129 - Frontal windshield frames and Continuity Fittings ALI 531129 Frontal windshield frame TH 30 600 FC (100%) Figures for post-mod 22058

HFEC of Windshield centre post, lower attachment area

Fasteners remain installed (bolt and nut should not be removed) Refer to AMM TASK 53-11-00-220-001-A & NTM 53-11-29

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage  ALI 531129 - Frontal windshield frames and Continuity Fittings Finding rate: Low

Finding rate: High

WINDSHIELD FRAMES



Generic repair instructions available  Repair kits available. Continuity Fittings: Repair by replacement (no access for rework) Structural access required: Front titanium panel removal Repair duration 1 week (access, structural work, close up)

Windshield Frames: Major repair by frame replacement Structural access required: Titanium panel, crown panel + fittings, lateral panel ( partially) removal Repair duration 3 weeks (access, structural work, close up)

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage  ALI 531129 - Frontal windshield frames and Continuity Fittings ALI 531129 Frontal windshield frame TH 30 600 FC (100%) Figures for post-mod 22058

WAY FORWARD • •

ISB 53-1245 will be updated to cancel and replace ALI (End 2015) Inspection will be done through ISB

•

Design improvement under study for forward fit.

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage MRB 531125 - Lateral sliding window frame MRB 531125 Lateral sliding window frame TH 48 000 FC/ 96 000 FH (100%) ALI 531133 TH 26 700 FC ALI 531105 TH 27 600 FC ALI 531130 TH 48 000 FC

MRB 531125 DET of Central/Lateral window frame around fastener

Fasteners remain installed (bolt and nut should not be removed) Refer to AMM TASK 53-11-00-220-805-A

Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage MRB 531125 - Lateral sliding window frame Finding rate: Medium POSSIBLE CRACK



Generic repair instructions available  Repair kits available. Lateral window frames: Major repair by frame replacement Structural access required: Lateral panel, crown panel, upp er panel (partially) removal Repair duration 2 weeks (access, structural work, close up)

Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage  ALI 531125 - Lateral sliding window frame MRB 531125 Lateral sliding window frame TH 48 000 FC (100%) ALI 531133 TH 26 700 FC ALI 531105 TH 27 600 FC ALI 531130 TH 48 000 FC

WAY FORWARD • •

Inspection will be done through ISBs ISBs will cancel and replace MRB/ALIs

•

Design improvement under study for forward fit

Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage  ALI 531110 - Cross beam splicing FR16/20 ALI 531110 Cross beam splicing FR16/20 TH 34 700 FC/ 69 400 FH

Roto-test of holes at Crossbeam Splicing, FR16 and FR20.

 Additional inspection requirements (2 first upper fastener rows) LH/RH frames 16 and 20 to be inspected at the same time.

2 upper fasteners rows in addition to the 4 required holes

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage  ALI 531110 - Cross beam splicing FR16/20 Finding rate: High

Standard repairs: Oversized fasteners + cold working Repair bushes + cold working

Major repair by frame replacement (low probability): 4 cases so far for A/C having more than 40 000FC out of more than two hundred A/C inspected Repair duration 2 weeks (access, structural work, close up)



Generic repair instructions available  Repair kits available.

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage  ALI 531110 - Cross beam splicing FR16/20 ALI 531110 Cross beam splicing FR16/20 TH 34 700 FC/ 69 400 FH

Crack length critical Interval Safe Crack Growth Period

WAY FORWARD • • • •

ISB 53-1286 cancels ALI, provides repair instruction and introduce economical threshold MSB 53-1295 cancels ISB requirement SBs expected Q2 2015 Serial mod (cold working)

detectable

FC FCdet

Mandated TH 34 700FC Recommended TH 21 700FC

FCcrit

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

 ALI/ISB – Section Forward Fuselage FR35

FR24

NO CRITICAL TASK IDENTIFIED

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

 ALI/ISB – Section Centre fuselage ALI 533180 Upper surface of pressure deck membranes TH 48 100 FC ALI 533181 Longitudinal beams flanges TH 48 500 FC ALI 532166 ALI 533186 FR 35 forward face to pressure bulkhead TH 43 400 / 40 000 FC MSB 53-1268 (optional)

ALI 533140 FR 47 splice plate circumferential skin splice TH 40 300 FC

ISB 53-1269/MSB 53-1270 Frame foot at FR43 RH/LH TH 40 000 FC ISB 53-1258/MSB 53-1251 Side box beam flange FR43 TH 24 000 FC

ALI 533185 Pressure membrane FR35-36 TH 48 000 FC

ISB 53-1259 Ti-angle keel beam side panel FR40-FR42 TH 30 000 FC

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

 ALI/ISB – Section Aft and Rear fuselage

ALI 534124 Upper corner aft pax door FR 68 TH 32 700 FC

ISB 53-1260/MSB 53-1271 Splice plate FR47 butt joint P5-P7 (LH/RH) TH 30 700 FC

ALI 534129 ALI 534130 Door stop fittings FR 66/68 TH 34 100 FC

ISB 53-1257/MSB 53-1261 Tack holes at FR50-FR63 (LH only) TH 38 200 FC

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Rear fuselage  ALI 534129 FR66 / ALI 534130 FR68 - door stop fittings holes ALI 534129 40 200 FC