December 6, 2024 - No. 49 In This Issue : FAA Mandates Boeing 737 MAX Spoiler Wire Checks : FAA not taking immediate steps to address 737 Max engine smoke concern : First Qantas A321XLR progresses to final assembly line : Purdue aviation experts create safety guard for Piper Archer aircraft in the Purdue fleet : Boeing Secures $1.7B Navy Contract Modification for Additional P-8A Aircraft, Engineering : Fokker and Airbus to establish H225M maintenance capabilities in the Netherlands : Fokker and Airbus to establish H225M maintenance capabilities in the Netherlands : Skyryse, ACE partner to make hundreds of Black Hawk helicopters easy enough for anyone to fly : Delta’s 757s Could Be Sticking Around : Qatar Airways expands MRO capabilities with landmark APU deal FAA Mandates Boeing 737 MAX Spoiler Wire Checks Helwing Villamizar December 2, 2024 DALLAS — The Federal Aviation Administration (FAA) has issued an airworthiness directive (AD) for the Boeing 737-8, 737-9, and 8-200 models to address potential issues with their spoiler wire bundles. As per the AD, improper installation of these wire bundles could lead to unintended spoiler movement, increasing the risk of a "hardover" event, where a control surface moves to its structural limit, potentially compromising the aircraft's control. The directive emphasizes the FAA's ongoing oversight of Boeing 737 MAX safety concerns, reinforcing the importance of precise inspections to prevent potentially catastrophic incidents. Key Incident The AD follows a December 2021 incident involving a Boeing 737-8 that rolled 30 degrees to the right due to spoiler malfunctions. Pilots observed a “SPOILERS” warning light but encountered difficulties referencing the issue in the flight manual. Though the aircraft landed safely, the spoiler "hardover" scenario had been noted in the plane's logbook days earlier. A spoiler hardover scenario occurs when a spoiler on an aircraft moves to its extreme position, or "hard limit," without proper control input. Spoilers are surfaces on the wings that reduce lift and assist with roll control or braking. In a hardover, unintended or incorrect positioning of the spoiler can: • Compromise control: If a spoiler on one wing deploys fully without an opposing action on the other wing, it can create an imbalance, potentially causing the aircraft to roll unexpectedly. • Stress pilot response: Pilots must quickly counteract the motion using ailerons or other controls to maintain stable flight. • Increase risks: If multiple spoilers on the same wing experience hardover, it may exceed the lateral control capabilities of the aircraft, leading to a potential loss of control. This condition can arise from mechanical failure, wiring issues, or software anomalies, making proper installation and maintenance of spoiler systems critical for safety. FAA not taking immediate steps to address 737 Max engine smoke concern By Jon Hemmerdinger 27 November 2024 US regulator the Federal Aviation Administration (FAA) will take no immediate action to address a smoke-related issue involving the CFM International Leap-1B engines that power the Boeing 737 Max. The concern involves a Leap system called the “load reduction device” (LRD) that is intended to activate in response to severe engine damage and that can cause smoke to fill either the jet’s cabin or cockpit. Two Southwest Airlines 737 Max suffered such incidents in 2023 after striking birds shortly after take-off. An FAA safety panel issued a report on 28 October recommending that the FAA address the concern, requiring that pilots follow different take-off procedures. It also recommended a design change intended to close a valve more quickly after a Leap-1B suffers a bird strike or loses a fan blade. Source: Boeing The FAA now says it does not intend to immediately act on those recommendations. On 26 November, the agency convened a “Corrective Action Review Board” to evaluate the LRD-smoke issue and to consider “several internal FAA safety recommendations”. “Based on the available data, the [board] determined the issue does not warrant immediate action and the FAA will follow its standard rulemaking process to address it,” the agency says. The FAA also plans to “issue a Continued Airworthiness Notification to the international community about new information Boeing provided to operators of aircraft with Leap-1B engines. The new information contains enhanced instructions that direct flightcrews more quickly to the appropriate actions when they experience abnormal engine indications”. Boeing in February had addressed the concern in an Operations Manual Bulletin sent to 737 Max operators. “We are working with the authorities that are investigating these incidents. We continue to follow regulatory processes to properly address potential issues and ensure the continued safety of the global fleet,” Boeing says. CFM has said that LRDs are “proven” technologies used for more than two decades and that Leaps meet bird-ingestion regulatory requirements. The engine maker is working with regulators and Boeing “to determine if there are any learnings from recent events”, it has said. Also in February, 737 Max operators American Airlines and Southwest Airlines notified pilots of the LRD-smoke issue. In that guidance, the airlines told pilots to consider such an event an instance of “severe engine damage”, and instructed them to respond by completing three checklists, including one that calls for shutting down the engine. Some pilots are unhappy with the FAA’s decision. Dennis Tajer of the Allied Pilots Association, which represents American Airlines’ crews, notes that he and his colleagues were not even aware of the existence of the LRD system before this year. He questions whether the FAA’s forthcoming “enhanced instructions” will be sufficient, and says the current guidance of following three checklists is not. Tajer says an engine needs to be shut down immediately after an LRD activation to prevent smoke from entering the cabin. But the checklists must be completed methodically, meaning the engine cannot be safely shut off before smoke becomes a problem. “The enhanced procedures better [include] some way to protect passengers other than running three separate checklists in seconds,” Tajer says. In its 28 October report, the FAA safety panel – convened by the agency’s Office of Accident Investigation & Prevention – called the LRD-smoke problem an “immediate safety” concern. The report says smoke in the cockpit could prevent pilots seeing and cause distraction during a critical phase of flight, possibly “ultimately leading to a loss of control”. “It is not rational to expect flightcrew to be able to don oxygen masks and smoke goggles during a critical phase of flight such as rotation and lift-off,” the report says. It also warns of exposing passengers and crew to smoke containing possibly “lethal levels of aerosolised acrolein and formaldehyde”. The report recommends a software change that would close a bleed-air system valve faster than currently designed. In the meantime, it recommends that pilots take-off with at least the 737 Max’s left-side bleed air system disabled. The report notes that Boeing estimates a 737 Max will suffer an LRD activation roughly once yearly. First Qantas A321XLR progresses to final assembly line • December 2, 2024 • 11:05 am • MRO & Production • Airbus A321XLR, Qantas Group Qantas' firs A321XLR has entered the final assembly line at Airbus’ production facility in Hamburg, Germany © Airbus Qantas is one step closer to receiving its first Airbus A321XLR, as the aircraft has now entered the final assembly line at Airbus' production facility in Hamburg, Germany. This development marks a major milestone in the Qantas Group's fleet renewal programme, with key airframe components such as the forward and rear fuselage, wings, and the iconic Flying Kangaroo tail coming together. Scheduled for delivery in April 2025, this aircraft will be the first of 28 A321XLRs on firm order, with purchase rights for additional units. These will progressively replace the Group's ageing Boeing 737 fleet over the next decade. Meanwhile, QantasLink continues to expand its operations with the A220, with the fifth aircraft set to enter service by the end of this year. Earlier in November, Iberia became the first airline globally to operate a commercial flight with the A321XLR. When Qantas' inaugural A321XLR begins service next year, Australian travellers will be the first in the Asia-Pacific region to experience this cutting-edge aircraft. Initially deployed on domestic routes currently serviced by 737s, the A321XLR promises an enhanced customer experience, offering wider seats, larger windows, fast and free Wi-Fi and overhead bins with 60% more capacity for luggage than its predecessor. In preparation for the aircraft's arrival, Qantas Engineering has received nearly 800 new tools and pilot training is well underway. Pilots will undergo up to 60 hours in the new simulator before taking command in the cockpit. Qantas Group CEO Vanessa Hudson highlighted the milestone, attributing it to over two years of meticulous planning and collaboration across multiple teams. “These new aircraft are part of the biggest domestic fleet renewal programme in Qantas' history, which is bringing significant improvements for customers and career opportunities for our people” Hudson said. “The A321XLR is a fantastic aircraft, which provides a more comfortable flight for customers and the longer range will in time give us the opportunity to explore more non-stop routes and operate them more efficiently. “New aircraft mean more jobs, training and promotion opportunities for our people and we'll be training more than 240 pilots on the new aircraft over the next three years.” Purdue aviation experts create safety guard for Piper Archer aircraft in the Purdue fleet Luca Capecchi, a Purdue Polytechnic Institute student, demonstrates using the magneto safety guard in the flight deck of a Piper Archer aircraft at Purdue University Airport. The patented magneto safety guard was designed by aviation experts in the School of Aviation and Transportation Technology. (Purdue University photo/John O’Malley) November 13, 2024 Steve Martin WEST LAFAYETTE, Ind. — When they approach a Piper Archer aircraft at Purdue University Airport, student pilots and maintenance personnel know with certainty that the engine and propeller are turned off thanks to a safety device created by Purdue Polytechnic Institute experts, which is now available for licensing. Michael Davis and Jon Ziulkowski have designed and implemented patented magneto safety guards for all 18 Piper Archer aircraft in Purdue’s fleet. Davis is the director of aircraft maintenance, and Ziulkowski is a senior lecturer and Part 141 flight operations quality assessment manager in the School of Aviation and Transportation Technology. “The guard is a clip that fits over the magneto switch at the top of the flight deck only when it is turned off,” Ziulkowski said. “While the clip is in place, the engine cannot be powered on; when the engine is on, the clip cannot be placed over the switch. A footlong ‘remove before flight’ ribbon attached to the clip provides a visual indication to people outside the flight deck that the clip is in place.” Michael Davis, left, and Jon Ziulkowski of Purdue Polytechnic Institute have designed a safety guard that fits over the magneto switch of Piper Archer aircraft in Purdue University’s fleet. (Purdue University photo/John O’Malley) Davis said, “We also have designed the clip to accept a lock that keeps the guard in place. This prevents our students from accidentally attempting to power up an aircraft that is down for maintenance or inspection.” Davis and Ziulkowski disclosed the magneto safety guard to the Purdue Innovates Office of Technology Commercialization, which has applied for a patent that protects the intellectual property. Industry partners interested in commercializing it should contact Matt Halladay, senior business development manager and licensing manager — physical sciences, at mrhalladay@prf.org, about track code 69452. Magnetos and safety A magneto is a self-contained electrical generator that provides spark plugs in an aircraft’s internal combustion engine with the energy needed to ignite the fuel-air mixture. When the magneto switch is on, the craft’s engine and propeller remain on with no external indication of their status. A Purdue-designed magneto safety guard hangs in place in a Piper Archer aircraft at Purdue University Airport. (Purdue University photo/John O’Malley) The magneto switch in the Piper Archer aircraft is part of an overhead line of switches in the flight deck. Davis said before the magneto safety guard was implemented for the Purdue fleet, it was a common occurrence for student pilots to forget to turn off the switches. “Purdue students fly the 18 Piper Archer aircraft five to six times per day, six days per week and, weather permitting, extra time on Sunday,” Davis said. “Around 25 safety reports were filed for these occurrences after the Purdue fleet was upgraded to the newest models in 2020. Since the magneto safety guard and lock have been used, no safety reports have been filed for accidentally leaving the magneto switch on.” The safety guards for the Purdue fleet were manufactured in the Indiana Manufacturing Institute, located in the Purdue Research Park of West Lafayette. “The rapid design-to-prototype step afforded through our School of Aviation and Transportation Technology colleagues in the IMI helped us to greatly shorten the time between modifications to find the perfect design in far less time than in similar projects I have done in industry,” Ziulkowski said. Boeing Secures $1.7B Navy Contract Modification for Additional P-8A Aircraft, Engineering • Elodie Collins • November 25, 2024 • Contract Awards Boeing has secured a contract modification valued at $1.68 billion to manufacture and deliver seven Lot 13 P-8A Poseidon maritime patrol aircraft to the U.S. Navy. The Department of Defense said Thursday the deal includes foreign military sales of non-recurring engineering for the governments of Canada and Germany. Work will be performed in Seattle, Washington, and various locations within the continental United States until September 2030. The Naval Air Systems Command Patuxent River in Maryland serves as the contracting activity. In a statement, Victoria Peterson, vice president and P-8 program manager at Boeing, commented that the order for additional Poseidons reflects the Navy’s commitment to maintaining a robust maritime presence and her company’s dedication to providing the military with safe and reliable platforms. “We look forward to delivering these additional P-8A maritime patrol aircraft to ensure the continued safety and security of our nation and allies,” she said. Boeing’s P-8A Aircraft The P-8A Poseidon is capable of conducting anti-submarine warfare, anti-surface warfare, search and rescue, and intelligence, surveillance and reconnaissance operations. It is equipped with synthetic aperture radar, electro and optical infrared sensor turret, and air-to-air refuel capability for long-range travels. P-8A Fleet Around the World Boeing currently has on contract a total of 207 P-8As, about 135 of which are for the U.S. Navy. In June, the aerospace company delivered six multi-mission aircraft to the Naval Air Command in Pohang, South Korea. Canada and Germany also are awaiting delivery of 17 Poseidon planes from Boeing under a $3.4 billion contract the U.S. Navy awarded in March. Australia, India, New Zealand, Norway and the U.K. are also among the few countries around the world that operate the P-8. Fokker and Airbus to establish H225M maintenance capabilities in the Netherlands By Defence Industry Europe Photo: Dutch Ministry of Defence. Fokker Services Group (FSG) has signed a Memorandum of Understanding (MoU) with Airbus Helicopters during the NIDV Exhibition Defence & Security in Rotterdam. The agreement aims to establish base maintenance capabilities for the H225M helicopters in the Netherlands, supporting the Royal Netherlands Air Force (RNLAF). This development follows the Dutch Ministry of Defence’s decision to acquire 12 H225M helicopters for the RNLAF. The partnership will provide local, comprehensive maintenance solutions, ensuring the RNLAF can access dependable support for the H225M fleet when needed. Airbus Helicopters, recognised for its expertise in rotorcraft engineering and maintenance, will contribute its extensive knowledge of the H225M platform. FSG, a trusted maintenance partner for the RNLAF’s NH90 NATO Frigate Helicopter, will bring its sustainment and operational experience to the collaboration. Commenting on the agreement, Roland van Dijk, CEO of FSG, said, “The H225M Base Maintenance capability will be an excellent fit with our current capabilities and our ambition to grow as a strategic maintenance partner for the RNLAF. We are thrilled that we will collaborate with Airbus Helicopters to bring this capability to the maintenance valley in Woensdrecht.” Alain Krief, Head of Region Industrial Participation for Europe at Airbus Helicopters, highlighted the long-term benefits of the partnership: “Together, our common strengths form a robust foundation for bringing valuable services towards RNLAF. In particular, RNLAF and FSG will respectively benefit from higher fleet availability and high-end skilled jobs on a long-term basis.” Skyryse, ACE partner to make hundreds of Black Hawk helicopters easy enough for anyone to fly News provided by Skyryse Nov 21, 2024, 12:01 ET EL SEGUNDO, Calif. and GUNTERSVILLE, Ala., Nov. 21, 2024 /PRNewswire/ -- Skyryse®, the creator of SkyOS™, the world's first universal operating system for flight, has signed a strategic partnership with Ace Aeronautics, LLC ("ACE") a major reseller of Black Hawk helicopters around the world. The agreement paves the way for Skyryse and ACE to equip hundreds of Black Hawk helicopters with SkyOS, transforming the highly-capable Black Hawk into the world's safest and simplest aircraft to fly. Assembly floor at Ace Aeronautics, LLC, one of the world's largest resellers of Black Hawk helicopters. Two iconic Black Hawk helicopters flying in formation. Logo for Ace Aeronautics, LLC ("ACE") Under the partnership, ACE's facility in Guntersville, Alabama, will serve as the primary installation hub for retrofitting Black Hawk helicopters with SkyOS. The Black Hawk comprises the largest fleet of helicopters in the world and will be in service for years to come. This collaboration addresses the rising demand for more advanced, safer, and user-friendly aviation solutions in the civilian market, particularly for public safety, search and rescue, and other critical life-saving services. ACE also sells Black Hawks in foreign markets representing an opportunity to introduce SkyOS in offshore markets. "Skyryse's mission is to make flying so simple that anyone can pilot any aircraft," said Dr. Mark Groden, CEO of Skyryse. "For 85 years, helicopters have been flown using the same mechanical controls that Igor Sikorsky used in his first flight. We're thrilled to be partnering with Ace Aeronautics to use SkyOS to bring unprecedented simplicity and safety to the most iconic aircraft to wear Sikorsky's name, allowing operators of all experience levels to fly with confidence." ACE's CEO Rich Enderle shared his enthusiasm for the partnership: "The Black Hawk helicopter is a proven workhorse that has performed countless missions around the world for almost 50 years. Today in partnership with Skyryse, we're ushering in a new era of possibilities. We're excited to partner with the leader in rotorcraft flight controls to enhance the safety and operational capability of the aircraft, and we're looking forward to seeing SkyOS elevate the experience for our customers." The integration of SkyOS into ACE's Black Hawk fleet promises to set a new industry benchmark for innovation, providing operators with a seamless, safer flight experience, and unlocking the capability to make every Black Hawk optionally-piloted for high-risk or non-passenger missions. For more information on Skyryse and SkyOS, please visit the Skyryse website. About Skyryse, Inc. Founded in 2016, the mission of Los Angeles-based Skyryse® is to bring about a new era in flight, with a goal of zero fatalities, and where piloting any aircraft is simple and safe. Their proprietary SkyOS™ universal operating system for flight – which powers their first aircraft, the Skyryse One™ – gives pilots greater control by simplifying the management of an aircraft during standard flight operations, inclement weather, and emergencies. Skyryse has raised more than $300 million from leading investors, including Fidelity Management & Research Company, Monashee Investment Management, Positive Sum, ArrowMark Partners, Venrock, Eclipse Ventures, Cantos, Stanford University, and Bill Ford, Executive Chair, Ford Motor Company. For more information, visit www.Skyryse.com or watch videos of Skyryse in action on YouTube. About Ace Aeronautics, LLC Founded in 2015, Ace Aeronautics (ACE) was established specifically to develop cockpit upgrades for the UH60 Blackhawk helicopter. Today, the overarching objective of ACE is to provide both aircraft that have undergone airframe and avionics upgrades which minimize obsolescence challenges facing operators around the world through industry best practices and a forward-thinking design. ACE currently supports numerous aircraft fleets operating around the world in Austria, Portugal, Ukraine and here in the US. Ace Aeronautics' executive staff offers more than 150 years of collective experience in global defense aerospace industries that span numerous specialties including business management; military and commercial program management; military aviation commands; manufacturing, design, integration, qualification/certification; and experimental flight test. ACE operates with a sincere commitment to Quality, Integrity, Safety and Ethics in all of our business ventures. We take pride in the professionalism of our personnel who are focused on customer satisfaction and the success of our entire team. SOURCE Skyryse Delta’s 757s Could Be Sticking Around With 737 MAX deliveries uncertain, the carrier might extend the aging fleet’s life. A Delta 757-300 aircraft (Photo: AirlineGeeks | William Derrickson) [ Planes ]November 21, 2024 1:38 pm ET By Ryan Ewing Delta’s fleet of 121 Boeing 757-200 and 757-300 aircraft might remain in service longer than expected amid aircraft delivery delays. The airline has orders for 100 737 MAX 10 aircraft, which has yet to receive FAA approval. With an average age of 27 years old, some of Delta’s 757s are among the oldest aircraft still operating at major U.S. airlines. According to Cirium Fleet Analyzer data, the airline has retired just one 757-200 this year, registered as N671DN. During a recent earnings call, Delta’s finance chief, Dan Janki, said the airline would begin retiring aircraft again in 2024, adding that it hadn’t removed any in 2022 or 2023. Janki initially indicated that Delta would retire around 20 jets from its entire fleet this year. A Delta Air Lines Boeing 757 climbs out of Eagle County Airport. (Photo: AirlineGeeks | William Derrickson) Flexibility Around Boeing At Delta’s Investor Day event on Wednesday, airline executives noted that the 737 MAX 10s aren’t in its near-term fleet plan. “We will have to continue to see where Boeing progresses related to the MAX,” Janki shared. “… We’ll see the progress that they’ve made. … [W]e have flexibility around that and how we could manage.” Delta CEO Ed Bastian noted some contract flexibility with the beleaguered manufacturer “if the [MAX] 10 isn’t produced.” He added that the carrier could extend the life of its 757s and 737-800s as needed; many have been retrofitted with newer interiors in recent years. Inside a Delta 757’s first class cabin (Photo: AirlineGeeks | William Derrickson) “You’re also going to see us potentially extend lives on whether it’s the 757s or [737-800s],” Bastian said. “We have the capability to do that, and we’ve been known to do that over time … . [T]hat could also be part of the mix here too.” Qatar Airways expands MRO capabilities with landmark APU deal • December 2, 2024 • 1:08 pm • MRO & Production • Honeywell Aerospace, Qatar Airways Representatives from Honeywell and Qatar Airways © Qatar Airways Qatar Airways has secured a ground-breaking agreement with Honeywell, becoming the first MRO provider in the Middle East and Africa authorised to service the HGT1700 auxiliary power unit (APU) used in Airbus A350 aircraft. This milestone represents a significant step forward for Qatar Airways in the aviation maintenance sector. The HGT1700 APU, located in the tail of the Airbus A350, supplies critical electric and pneumatic power to the aircraft's systems, including its main engines. With this agreement, Qatar Airways will not only generate additional revenue but also save on maintenance costs for its own fleet. This collaboration supports Qatar's Vision 2030 strategy, promoting economic diversification and positioning the nation as a hub for aerospace innovation. Qatar Airways Group Chief Executive Officer, Engr. Badr Mohammed Al-Meer, said: “This milestone marks a transformative step for Qatar Airways, as we enter the MRO sector. Alongside servicing our own fleet's APUs, we'll also generate new revenue streams by offering maintenance services to third-parties. This partnership not only reinforces our position as an industry leader but also enhances our profitability and capacity to deliver exceptional service to our partners.” A central element of the partnership is the development of a cutting-edge MRO facility, designed to service Honeywell's advanced HGT1700 APUs. This state-of-the-art site will incorporate eco-friendly and energy-efficient technology, setting new standards for maintenance excellence. Scheduled for completion by 2028, the facility will create over 50 high-skilled jobs, fostering local talent and attracting top global engineering expertise to Qatar. In addition to becoming a Honeywell Channel Partner, Qatar Airways will accelerate its timelines to induct its first APU for maintenance by 2028. This designation allows the airline to extend its maintenance services beyond its own fleet, marking a significant expansion in its business operations. Curt Lewis