Aircraft Tank Repair

7/21/2019 Aircraft Tank Repair

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101 Convention Center Drive Ste. 700

Las Vegas, NV 89109

Tel: 702 203-1633Fax: 702 447-7040

INTEGRATED SOLUTIONS FOR RAPID AIRFRAME REPAIRSAND MANUFACTURING IMPROVEMENTS

BACK IN THE AIR FASTER !BACK IN THE AIR FASTER !

BACK IN THE AIR FASTER!


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Engine Change 4 to 6 hours

R & R a component Few minutes to few hours

Repair Airframe Damage (Fuel Leaks) ........ Unknown, several hoursto several days!

COMPANY PHILOSOPHY


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Currently, a fuel leak typically takes 36 to 72 hours to be

repaired... (sometimes, a lot longer than that)!

AEROWINGs new technologies canreduce this time to 6 to 12 hours,

with very good reliability

TYPICAL EXAMPLE: FUEL LEAK


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Most Time Consuming Tasks when Repairing a Fuel Leak:

1.) Finding the leak source inside the tank

2.) De-sealing (removing) the faulty sealant

3.) Cure time for new sealant

4.) Quality control of the repair (Soak Check) -In the event of a re-leak, the clock starts again from zero!

THE FOUR MOST TIME CONSUMING TASKS


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SAME METHODS SINCE 1940s

Most Common Methods Currently Used for Finding Fuel Leaks:

Blow Back Method - High pressure air applied from the

outside leak point and searching for bubbles inside the tank

(admitted by Boeing to be around 60% accurate)

Dye Method Using low viscosity penetrating fluid

*


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It is the lightest and smallest inert gas molecule.

It easily flows through very small leak paths.

It permits non destructive and dynamic testing.

HELIUM IS A VERY LIGHT INERT GAS

NEW TECHNOLOGY - HELIUM LEAK DETECTION: WHY HELIUM?


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Helium is non toxic and non reactive.

Helium is non hazardous.

Helium is non flammable, nor explosive.

HELIUM IS SAFE

NEW TECHNOLOGY HELIUM LEAK DETECTION


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NEW TECHNOLOGY

AEROWING - Helium Leak Detection -

Proven by Boeing and Airbus to be 95 98% accurate inlocating leaks within the tank

Important Features: Portable, Intrinsically Safe, Accurate,Selectable Sensitivity, Auto Zero Feature

Able to be used for finding leaks in other aircraft systems(Pitot Static System, Oxygen System, EnvironmentalControl System, Engine Bleed Air System, etc.)


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AIRCRAFT LEAK DETECTION NEEDSAIRCRAFT LEAK DETECTION NEEDS

Fuel tank pipes, venting systems

Oxygen lines in cockpit and cabin

Pitot-static circuits

Engine fire suppression

Windshield, windows and doors

Other components : Bladder Cells, Valves, Slides, etc

Engine Bleed System


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HELIUM METHOD ADVANTAGESHELIUM METHOD ADVANTAGES

Helium is 1000 times more sensitive than bubble.

Helium allows dry testing, better for health and safety.

Helium allows dry quality control for rapid repair cycle and

less expensive testing.


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HELIUM METHODHELIUM METHOD -- FUEL LEAK MAPPINGFUEL LEAK MAPPING

Very precise external mapping is mandatory for

successful internal location of the leak.

Leaking areaLeaking area

OUTSIDE

INSIDEINSIDE


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HELIUM METHODHELIUM METHOD -- HELIUM PRESSUREHELIUM PRESSURE

External Leak

Location

The application of Helium pressure on the external leak point

will allow the internal leak source detection.

FUEL LEAK

=

Location of sealant

deterioration


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HELIUM METHODHELIUM METHOD -- HELIUM FLOW DETECTIONHELIUM FLOW DETECTION

Helium, which follows the leak path, can be detected inside.

OUTSIDE

INSIDE(Fuel tank)

SkinSkin

RibRib

HELIUMHELIUM

Helium DetectorHelium Detector

SnifferSniffer


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HELITEST WING KITHELITEST WING KIT Listed in T.O. for KC-135 fleet and C-5depot use (Robins, AFB)

Helitest Wing 3.0 Aircraft Helium Leak Detector Kit

Safety Probe for

use in hazardous

environments

Class 1, Div. 1

(30 foot hose)


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HELITEST WING CONCEPTHELITEST WING CONCEPT

*

Helitest PHD-4 with local probe = portability (5 lbs.).

For use in verifying leak repair BEFORE refueling.


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RAPID DESEALINGRAPID DESEALING

DAYS TO REMOVE SEALANT:

Current method - scrape sealant by hand using pieces of

plastic or aluminum fashioned as cutting tools

Existing sealant can be 2-3 inches thick with multiple layers

Difficult areas to work inside (and outside) the tank


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RAPID DESEALING SYSTEMRAPID DESEALING SYSTEM

Composite Material Blade

Will Not Harm Structure

Will Not Scratch Primer

Standard Shop Air

50 Units in Use

at Tinker AFBKC-135 PDM

Variable Speed Control


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Rapid Curing

Standard Tank Sealants Can Take 24 or More Hours to Cure(depending on ambient temperatures and humidity, the colder itis, the longer it takes to cure)

Quick Repair Sealants Deteriorate Much Sooner ThanStandard Repair Sealants (not designed to be permanent repairmaterial)

Two Configurations Aircraft Repair and Aircraft Manufacturing


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RAPID CURING DEVICERAPID CURING DEVICE


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ABSORPTION SPECTRUM OF

PAINT AND SEALANTS

EMISSION SPECTRUM OF THE

THERMOREACTOR 28 Vdc

0

20

3040

50

60

70

80

90

100

2 3 4 5 6 7 8 9 10

10

WAVELENGTH (in microns)

0

10

20

30

40

50

60

70

80

90

100

2 3 4 5 6 7 8 9 10

WAVELENGTH (in microns)


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-Warm air

Thermoreactor

28Vdc

Thermoreactor

28Vdc

-Electrical infrared source

like heat lamp

-Electrical infrared source

like heat lamp

Narrow Spectrum of Infra RedNarrow Spectrum of Infra Red

Wide Spectrum EmissionWide Spectrum Emission

= poor energy transfer= poor energy transfer

= good energy transfer= good energy transfer

DANGER:

ignition risk

Complete safetyComplete safety

Poor absorptionPoor absorption

Excellent absorptionExcellent absorption

SEALANTSEALANT

Trapped solvents

= bubbling risk

Trapped solvents

= bubbling risk

Superficial dryingSuperficial drying

Incomplete

polymerization

Incomplete

polymerization

Evaporated solvents =

no micro bubbling risk

Evaporated solvents =

no micro bubbling risk

Equal polymerization

throughout the

material.

Equal polymerization

throughout the

material.

RAPID CURING DEVICERAPID CURING DEVICE As heat lamp is appl ied, material forms a skin, t rappingsolvents and micro bubbles

Infra Red

Signal fromheat lamp

Infra Red Signal

from

Thermoreactor

No surface skin


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30 hours standard cure30 hours standard cure

72 hours standard cure72 hours standard cure

2.75 hours with

Thermoreactor

2.75 hours wi th

Thermoreactor

6 hours6 hours

Sealant PR 1422 B2 NA

Reference hardness

Tack free time

0

5

10

15

20

25

30

35

40

45

50

55

60

0 10 20 30 40 50 60 70 80

Hardness

Time

(hours)

(fuel leak repair)

Manufacturers suggested temperature

and humidity condit ions ( 73.4F 50% )With the Thermoreactor 28 Vdc at 122F


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170 hours standard cure170 hours standard cure5 hours5 hours

Reference hardness

0 50 100 150 200

50

100

150

200

250

300

0

Hardness

Time

(hours)

Polyurethane paint PU66 ( COURTAULDS )

Usual temperature and hygrometry

conditions ( 73.4F 50% )

Usual temperature and hygrometry

conditions ( 73.4F 50% )With the Thermoreactor 28 Vdc at 122FWith the Thermoreactor 28 Vdc at 122F


M f t i C fi ti


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Manufacturing Configuration

Operated by Factory A.C. ElectricalPower

*

T k P i ti S t TPS


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Tank Pressurization System TPS

Easily configured to most aircraft tank systems

TPS: VENT PLUGS


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TPS: VENT PLUGS

A new generation

of

Vent Plugs

~

No parts removal / Rapid Testing

Patented ProcessPatented Process

TPS: CONTROL PANEL


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TPS: CONTROL PANEL

REFERENCES COMMERCIAL AIRLINESREFERENCES COMMERCIAL AIRLINES
http://../TPS%20english.ppt


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REFERENCES: COMMERCIAL AIRLINESREFERENCES: COMMERCIAL AIRLINES

DELTA UNITED AA US AIRWAYS

AIR CANADA AEROMEXICO

CANADIAN REGIONAL HORIZON

LUFTHANSA AIR FRANCE

BRITISH AIRWAYS SCANDINAVIAN

SABENA TECHNIC TAP CITY LINE

SOGERMA

AIR AFRIQUE EGYPT AIR EMIRATES

JAREMCO GAMCO CHINA AIRLINES

CATHAY AIR CHINA THAI AIRWAYSSINGAPORE AIRLINES QANTAS

KOREAN

REFERENCES AIRCRAFT MANUFACTURERSREFERENCES : AIRCRAFT MANUFACTURERS


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REFERENCES : AIRCRAFT MANUFACTURERSREFERENCES : AIRCRAFT MANUFACTURERS

BOEING, SEATTLE (all commercial fleets)

BOEING, ST. LOUISNORTHROP GRUMMAN

GULFSTREAM

VOUGHT AIRCRAFT

BOMBARDIER

EMBRAER

EADS

AIRBUS (all commercial fleets)

DASSAULT AVIATIONEUROCOPTER

REFERENCES: MILITARY MARKETREFERENCES: MILITARY MARKET


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REFERENCES: MILITARY MARKETREFERENCES: MILITARY MARKET

USAF: TINKER HILL ROBINS

Helitest Wing Kit

Reference

T.O. 1C-135-2-5-2

T.O. C-5 depot use

U.S. AIR NATIONAL GUARD

U. S. MARINE CORPS

US NAVY:

NAS JACKSONVILLE DEPOT

FRENCH AIR FORCE

FRENCH NAVY

GERMAN AIR FORCE

ITALIAN AIR FORCE

ROYAL AUSTRALIAN AIR FORCE

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Aircraft Tank Repair