WAPA 2010

1. Federal Aviation Administration WAPA 2010 Tim Smyth (847) 294-7132 timothy.smyth@faa.gov Representing the FAA

2. Federal Aviation Administration This Year’s IssuesWestern Aircraft Propeller Service (Update)Hartzell Propeller Hub Oil Filling EffortALCOA Forging InvestigationFuture of FAA A/C Certification Support

3. Federal Aviation Administration • Doing this presentation as a public awareness and education effort. • Currently employed as a Senior Engineer, Propulsion Branch at the Chicago ACO. • Hartzell Propeller FAA Program Engineer and Organization Designation Authorization (ODA) Oversight Management Team (OMT) Lead

4. Federal Aviation Administration Western Aircraft Propeller Service (Update) SAIB NE-09-48, issued August 14, 2009 SUBJECT: Potential Nonconformities Background: (Revisit the reason this all started) How/Why did this happen? • Baron aircraft owner complaint! • “Improper overhaul(s) alleged” • Portland FSDO was contacted

5. Federal Aviation Administration SAIB NE-09-48(cont.) • Propellers removed and sent to another repair station for teardown and evaluation. • FAA Principal Maintenance Inspector (PMI) witnessed • Several nonconformities were discovered • “Slimcerts” not installed • Unauthorized shotpeening performed • Wrong finish paint used • Pitch change knobs improperly installed • Damaged hub threads • Damaged cylinder threads • EC776 sealer used but not appropriate • PMI decided to send propeller assemblies to Hartzell for further evaluation • Hartzell confirmed findings

6. Federal Aviation Administration SAIB NE-09-48(cont.) Because of the previously described conditions…. • Portland FSDO performed a focused repair station facility inspection, they found; • Signed off AD compliance without proper NDI qualifications • Out of date vision tests • Employee certifications expired • Training requirements not current • Calibration of equip out of date • Shop equipment out of calibration • No facility shotpeening qualifications • Process did not meet TC holders requirements • Chemical conversion coating not applied in accordance with TC holder’s requirements • Used parts tagged (8130-3) without reference or traceability to FAA approved or accepted data • Facility DID NOT perform all the steps cited in TC holder’s ICA documentation for overhaul

7. Federal Aviation Administration SAIB NE-09-48(cont.) • Western Aircraft Propeller Service has worked hard to correct these findings • Propeller and propeller components returned to service after July 1, 2009, are not subject to this SAIB • FAA has returned Western Propeller’s Repair Station Certificate to full capability active status • FAA re-issued SAIB NE-09-48R1to notify the public of Western Aircraft Propeller Service’s corrective actions and “Status” (Sept. 24, 2010)

8. Federal Aviation Administration SAIB NE-09-48 (cont.) What can we all learn from this (Reminder)? • You never know when a complaint will generate an investigation • Keep records and certifications up to date • Maintain your agreements with the FAA and the propeller mfgrs • Make sure equipment calibrations are current • Work to the propeller manufacturer’s publications or other FAA approved/accepted data • Use the latest revisions (recommendation) • Make sure special processes are properly qualified/approved • Maintain frequent communications with your local FAA/CAA representative • Don’t forget FAA voluntary disclosure policies (AC 00-58B) • Self Audit your facility • Present findings to FAA prior to their investigation visit • Propose a corrective action plan • Show evidence you are correcting the issues found • Finally conduct a safety assessment on self audit findings • Study FAA website on Safety Management (advisory matl)

9. Federal Aviation Administration Hartzell Hub Oil Filling Effort (Ref. M. Mayhill Pres.) Why? • Number of hub cracks/failures over the years • Cause HAS NOT been specifically identified • Design improvements have helped • Several ADs written over the years • Thousands of inspections performed • NO DETECTED CRACKS to date • BUT...small number of hub cracks still reported every year • Previous success with oil filling hubs • Develop a terminating action to maintain safety (Goal) • Reduce burden on flying public

10. Federal Aviation Administration Hartzell Hub Oil Filling Effort (cont.) What’s been going on? • FAA has been encouraging Hartzell’s development program • Extensive design and field evaluation effort • Approximately three year program • Service Evaluation almost complete • FAA ready to implement when Hartzell is ready • AD Alternative Method of Compliance is being considered

11. Federal Aviation Administration Alcoa Blade Forging Investigation What’s going on here? • To date, two reports of internal blade forging defects found • All solid aluminum blade forgings made by ALCOA potentially involved • Affects all propeller manufacturers that use solid aluminum blade forgings from ALCOA • NO failures to date • Defect may be introduced at the Ingot to Bar shaping level material process (ALCOA investigation findings) • Blade shape forging process can stretch internal defect over large internal blade surface areas

12. Federal Aviation Administration Alcoa Blade Forging Investigation (cont) How is it found? • First report found during new blade production machining • Second report found during overhaul inspection • Both were found visually How many blades affected? • Not sure • Condition could be present over many years What do or can I do? • Get with the respective manufacturers for details • Report any unusual internal defects found (outboard blade section, blade bore, balance hole, etc.) Ongoing Industry/FAA effort continues…..

13. Federal Aviation Administration FAA Aircraft Certification Changes? Public awareness briefing: • A/C Certification Division is undergoing a transformation • What does that mean….? • A/C Certification appears to be going from a direct certification support activity with the public to an certification oversight activity for delegated authorizations? • What the….huh? • In the near future ACOs may be used to primarily conduct oversight of delegated certification authorizations in lieu of direct certification programs with the public. • Transition has started • Expect full change over to occur by 2015 or so • Changes to the Designated Engineering Representative (DER) Program in work. • Organization Designation Authorization (ODA) now in place (Since 2009) Why? • Academy of Sciences Study from 1996-1998 (Report to Congress) • Harmonization with the European Union (EU) • Industry promoting changes (Advisory Committee Participation)

14. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) • Academy of Science’s Report to Congress • Outlined streamlined and improved certification processes • Made recommendations to reduce certification burden • Proposed changes to standardize certification requirements • Harmonization with the EU • European Aviation Safety Authority (EASA) Current Structure • DOA (Organizational Certification Approval Authority) • Product Approval Holders (PAH) • Under DOA, PAHs control type design changes • Aircraft Operators/Users must obtain approvals from PAHs Note: many operators have used US DERs to obtain design approvals in US, then submit validation requests through Bi-Lateral trade agreements • Applicants must meet certain qualification standards to directly submit Type Design approval proposals to EASA • FAA proposes to harmonize with this type of structure • Proposed re-write to 14 Code of Federal Regulations (CFR) Part 21 coming next year • Notice for Proposed Rulemaking (NPRM) scheduled for release in 2011 To:

15. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) 14 CFR Part 21 Proposed Re-write (NPRM) (highlights, cont.) • 21.15, 21.21, 21.29; Establish certification applicant qualifications • Require demonstrated capability by applicants • Applicant must have an engineering system or hire designees • Similar qualification standards for STC applicants, etc. • Align with EASA • 21.47 Transfer • FAA reviews potential holder’s qualifications and capabilities • FAA agrees/approves transfer and reissues TC-STC • In line with EASA language and process • Standardize and enforce approval holders responsibilities • Other changes (Review NPRM)

16. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) FAA ODA Structure • ODA is an ACO like organization with “limited” certification approval authority. • ODAs can: • Issue PMA design approvals • Design approval for STCs and issue STCs • TC design approvals • Conduct inspections (conformities) • Provide approved data to other ODAs • Maintain/oversee Quality Systems for production • Receive repair and alteration design approval authority • Support FAA managed cert. programs • Other misc. authorities

17. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) FAA ODA Structure (cont.) • There are currently 160 + ODAs recognized and approved by the FAA • More are under review for approval • ODA structure is intended to be the means to obtain certification type design approvals in the future (Similar to EASA DOA) • FAA to rely on ODAs to conduct significant “day to day” certification program activities. • FAA to provide resources to oversee ODAs • FAA to transition to ODA oversight versus direct public certification programs once an ODA has approval for that function • Expect full implementation in the next 5 years or so

18. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) FAA DER Program Changes (highlights) • DER delegated authority to transition from function authority (e.g. Structures, Powerplant, Systems, etc.) to delegated authority by specific regulation (e.g. 23.907, 25.903, etc.) • Transition to occur (start) sometime in the next year (2011) or so • All DERS to receive delegated authority by regulation • If the DER doesn’t have the specific regulation callout in their authorization letter they can’t approve that data (find regulatory compliance) • DER will be evaluated yearly to determine if they have any activity to that regulation (find compliance) • If Yes, authority will likely be extended another year • If No, then FAA will determine if that regulation remains with that DER’s authority (yearly renewal) • DER numbers have diminished from approx. 4000 to less than 2000 (further reduction anticipated)

19. Federal Aviation Administration FAA Aircraft Certification Changes (cont.) FAA DER Program Changes (highlights) • RS-DER delegated authority (Repair Specifications) • An RS-DER is a DER who has a specialized delegated authority to approve multiple, non-serialized part or component (including sub-assemblies, etc) repair specifications. • Starting July 2011, ONLYRS-DERs can approve these type’s of repair specifications. • RS-DER must have this specific authority listed in the DER authorization letter (and Designee Information Network (DIN)) • RS-DER will sign the front page of the Repair Specification with his or her DER number • Other limitations on DERs are being proposed/implemented • Visit the FAA website for further information on DER changes

20. Federal Aviation Administration • Questions??? Thank You!