INTEGRATED SOLUTIONS FOR RAPID AIRFRAME REPAIRS AND MANUFACTURING IMPROVEMENTS

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101 Convention Center Drive Ste. 700 Las Vegas, NV 89109

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

INTEGRATED SOLUTIONS FOR RAPID AIRFRAME REPAIRS

AND MANUFACTURING IMPROVEMENTS

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 hours to several days!

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Currently, a fuel leak typically takes 36 to 72 hours to be repaired... (sometimes, a lot longer than that)!

AEROWING’s new technologies can

reduce 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!

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SAME METHODS SINCE 1940’s

• 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

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Helium is non toxic and non reactive. Helium is non hazardous.

Helium is non flammable, nor explosive.

HELIUM IS SAFE

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NEW TECHNOLOGY

• AEROWING Helium Leak Detection

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Proven by Boeing and Airbus to be 95 – 98% accurate in

locating 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, Environmental

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AIRCRAFT 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 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 METHOD

HELIUM METHOD - - FUEL LEAK MAPPINGFUEL LEAK MAPPING

Very precise external mapping is mandatory for successful internal location of the leak.

Leaking area

OUTSIDE

INSIDE

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HELIUM METHOD

HELIUM 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 METHOD

HELIUM METHOD - - HELIUM FLOW DETECTIONHELIUM FLOW DETECTION

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

OUTSIDE INSIDE (Fuel tank) Skin Skin Rib Rib HELIUM HELIUM Helium Detector Helium Detector “ “SnifferSniffer””

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HELITEST WING KIT

HELITEST WING KIT Listed in T.O. for KC-135 fleet and C-5 depot 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 CONCEPT

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

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RAPID DESEALING RAPID 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

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RAPID DESEALING SYSTEM

Composite Material Blade Will Not Harm Structure

Will Not Scratch Primer

Standard Shop Air

50 Units in Use at Tinker AFB

KC-135 PDM Variable Speed Control

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RAPID DESEALING SYSTEM

• Two Year Study to Determine Effectiveness

• Dramatically Reduces Desealing Time

• Efficiency Due to Resonance, Created Between

Sealant and Structure

• Replaceable Blades (can re-sharpen)

• Angle of Blade is Most Important Factor

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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 it is, the longer it takes to cure)

• “Quick Repair” Sealants Deteriorate Much Sooner Than

Standard Repair Sealants (not designed to be permanent repair material)

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RAPID CURING DEVICE

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ABSORPTION SPECTRUM OF PAINT AND SEALANTS

EMISSION SPECTRUM OF THE THERMOREACTOR 28 Vdc 0 20 30 40 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

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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 Red

Wide Spectrum Emission

= poor energy transfer = poor energy transfer

= good energy transfer = good energy transfer

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DANGER: ignition risk Complete safety Complete safety Poor absorption Poor absorption Excellent absorption Excellent absorption SEALANT SEALANT Trapped solvents = bubbling risk Trapped solvents = bubbling risk Superficial drying Superficial 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 DEVICE

RAPID CURING DEVICE As heat lamp is applied, material forms a skin, trapping solvents and micro bubbles

Infra Red Signal from

heat lamp

Infra Red Signal from Thermoreactor

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30 hours standard cure

2.75 hours with Thermoreactor 2.75 hours with Thermoreactor 6 hours 6 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)

Manufacturer’s suggested temperature and humidity conditions ( 73.4°F 50% ) With the Thermoreactor 28 Vdc at 122°F

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5 hours 5 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 ( 73.4°F 50% )

With the Thermoreactor 28 Vdc at 122°F

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Manufacturing Configuration

Operated by Factory A.C. Electrical Power

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Tank Pressurization System TPS

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TPS: VENT PLUGS

A new generation of

Vent Plugs ~

No parts removal / Rapid Testing

Patented Process

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REFERENCES: 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 AIRWAYS

SINGAPORE AIRLINES – QANTAS – KOREAN

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REFERENCES : AIRCRAFT MANUFACTURERS

BOEING, SEATTLE (all commercial fleets) BOEING, ST. LOUIS NORTHROP GRUMMAN GULFSTREAM VOUGHT AIRCRAFT BOMBARDIER EMBRAER EADS

AIRBUS (all commercial fleets) DASSAULT AVIATION

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REFERENCES: 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