Aircraft Repair Research Articles

Development of an Open-Source Robotic NDT Solution for Automated Composite Repair Testing

Abstract Non-destructive testing (NDT) plays an important role in aircraft maintenance and repair processes, ensuring the structural integrity necessary for safe operation. The paper presents the design and evaluation of an animated, low-cost robotic NDT system tailored for inspecting composite bonding agents. The system integrates commercially available components, including a three-degree-of-freedom robotic arm and a Raspberry Pi 4B, managed by custom Python software with a user-friendly graphical interface. Mechanical Impedance Analysis (MIA) and Eddy Current Testing (ET) methods were employed to assess the system’s performance on representative test specimens. Results indicate that the system delivers reliable and accurate measurements comparable to commercial tools like the MAUS V, while offering simplicity and modularity. Limitations such as scanning speed and handling of complex geometries are acknowledged, with potential solutions proposed for future enhancement. The system provides an affordable and customizable alternative for NDT automation in the aerospace industry.

DEVELOPMENT OF MODELS AND ALGORITHMS FOR DECISION-MAKING IN AIRCRAFT MAINTENANCE AND REPAIR TASKS BASED ON THE USE OF INFORMATION TECHNOLOGIES

This article provides detailed information on aircraft maintenance and repair using information technology. In addition, special attention is paid to the development of models and algorithms for solving these problems.

Satisfying the needs for highly qualified engineering staff in a disruptively changing aircraft industry with special care for MRO sector

PurposeThe number of passengers in the aviation sector following COVID-19 has recovered in 2023 and is 5% higher than it was in 2019. The average annual growth of air travel is predicted to be 3.2% between 2019 and 2039. This means the need for aircraft maintenance, repair and overhaul (MRO) services will also increase. Moreover, the stakeholders require lower costs, higher effectiveness/market share and sustainability. These expectations can be realized only with the identification, development and implementation of new innovations while improving and optimizing the already used processes and procedures. Since only highly qualified graduates can reach these requirements, the need for profession-specific MSc and PhD level engineers has elevated significantly. The purpose of this paper is to introduce the development and implementation of a new MRO higher educational framework program in strong cooperation with enterprises and universities.Design/methodology/approachThe emphasis is placed on the program’s scouting, investigation, development, realization and evaluation by defining key performance indexes and aiming for the optimal solution for all participants.FindingsThe result of this study is the establishment of a new educational framework, the reinvention of the MSc curriculum and the integration of PhD-level researchers in the industry in a way that fulfills the needs and requirements of the MRO sector. In return, it will give various benefits to all parties involved.Originality/valueThe novelty of this work comes from creating a new educational MSc and PhD level framework that can push the MRO industry forward and fill the gap of missing engineers in this field. Plus, the newly developed program is highly flexible and can be used by other players in the economy after making some adaptions and modifications.

Understanding no fault found event risk in military aircraft MRO planning: A step towards robust bidding and contract finalization

No fault found (NFF) is a reported fault for which the root cause cannot be found. An NFF event not only reduces the availability of the equipment to customers but also results in financial losses to the manufacturer. To date, risk due to NFF events is not considered separately in aircraft Maintenance, Repair, and Overhaul (MRO) planning. In this paper, we have studied the NFF event risk identification, distribution, and optimization in an aircraft MRO process based on data collected over three decades of aircraft maintenance. For framework development and formulating the critical NFF risk drivers, this paper applies soft system methodology with detailed semi-structured interviews of industry experts. For NFF risk distribution and optimization, we have used agent-based simulation modeling. The quantitative assessment of more than 5000 NFF cases in an aircraft MRO organization shows that NFF events are significantly non-deterministic during the life cycle of an aircraft. The three identified critical NFF risk drivers in the research are the MRO process stage, aircraft life cycle stage, and human working skills. The MRO process stage is the time of the NFF event during repair activity. The life cycle stage represents the timeline of the NFF event in useful aircraft life. Human working skill represents the role of manpower in the NFF event solution. Further theoretical elaborations of the research lead to the optimized NFF risk break-up at the contract preparation stage and risk driver's sensitivity analysis by the aircraft assembler, operator, and sub-contractor at the commercial bid submission stage.

Penerapan Strategic Approach Pada Kegiatan Company Visit PT. Garuda Maintenance Facility Aero Asia Tbk

PT Garuda Maintenance Facility Aero Asia Tbk (GMF) is a company engaged in aircraft maintenance, repair and overhaul (MRO). GMF has a business unit consisting of comprehensive aircraft maintenance, such as commercial aircraft maintenance, military aircraft maintenance and industrial services. At this company, the author took part in practical work activities in the Corporate Communications & CSR unit which is under the auspices of the Corporate Secretary & Legal service which carries out the public relations function at GMF. In this report, the author will explain the application of 4 strategic approaches to company visits held for GMF stakeholders using interview, observation and literature study methods. The stakeholder aspects that will be explained from the perspective of Grunig's 4 Linkage Model are functional linkage, enabling linkage, normative linkage, and diffused linkage. PT GMF approaches stakeholders using 4 strategic approaches, namely assertive, defensive, collaborative and responsive.

Exploratory Study of Sustainability Practices in Worldwide Major Aircraft Maintenance, Repair, and Overhaul Companies

While sustainable aviation research has primarily focused on the airline industry, aircraft manufacturing, and airport responsibilities, the aircraft maintenance, repair, and overhaul (MRO) industry’s contribution to achieving sustainable aviation goals has been overlooked. This study examines the approaches to corporate sustainability practices used by aircraft MRO companies worldwide. The methodology used to investigate the sustainability actions of major MRO companies globally was mainly based on observational data gathered from multiple data sources, such as environmental, social, and governance (ESG) and investor relations documents. Four companies out of the 13 major MRO companies whose sustainability reports were found are examined as a case study analysis. Each MRO company adopted different definitions and practices of sustainability. The findings show that the aircraft MRO sustainability definition varies among the major companies studied, but some commonalities can be used to develop a proposed definition. The authors propose that aircraft MRO sustainability be defined as the ability to conduct MRO business that positively affects all stakeholders while emphasizing safety, quality, and integrity values, using technology and innovation to make growth, and constantly stabilizing and/or diminishing the impact on the environment. This study contributes to the understanding of sustainable aviation by highlighting the role of MRO companies in achieving sustainable goals.

ИЗУЧЕНИЕ МАКРО- И МИКРОЭЛЕМЕНТНОГО СОСТАВА РОТОВОЙ ЖИДКОСТИ ПРИ ПРОВЕДЕНИИ ПРОФЕССИОНАЛЬНОГО ОТБЕЛИВАНИЯ ЗУБОВ

Aesthetic dentistry is one of the up-to-date trends in dentistry. There are a lot of methods targeted at eliminating discoloration, including teeth whitening. The dentist’s task is to choose the optimal whitening system. Patients, especially those who work in hazardous industries, are also interested in getting a snowwhite smile. The authors have conducted a comparative assessment of the effectiveness of a chemical activation system with a 37% concentration of hydrogen peroxide (USA) with a chemical activation system with a 35% concentration of carbamide peroxide (Russia). Changes in the chemical composition of oral fluid were revealed after the professional whitening procedure. The subject of the study is the chemical composition of oral fluid. The goal is to study the chemical composition of oral fluid during teeth whitening procedures. Methodology. The studies were carried out on the basis of the Department of Therapeutic Dentistry of the Federal State Budgetary Educational Institution of Higher Education “Privolzhsky Research Medical University” of the Ministry of Health of Russia, Autonomous Non-Profit Organization “Center for Biotic Medicine” of Dr. A.V. Skalny, State budgetary institution of the Ryazan region “Dental Clinic No. 1” (Ryazan). The study involved 50 patients of both sexes from 23 to 45 years old, who were employees of an aircraft repair plant in Ryazan. Patients were divided into two groups. A chemical study of oral fluid was performed for 50 people before teeth whitening and for 15 people, in the control group, after teeth whitening. Results. Determined macro- and micro elements differed in quantitative content between the studied groups. Comparing the obtained data of the concentration of elements in saliva with the results of the work of other researchers, we can conclude that there is a scattering in the results according to the literature, possibly due to the different “microelement” status of the regions in which the sample donors live. Conclusions. The results of the study demonstrate that both whitening systems have a pronounced effect on the chemical composition of the oral fluid, while the system based on 37% hydrogen peroxide led to a greater degree of normalization of the level of chemical elements in the oral fluid.

Optimization Design of Mechanical Properties of Frame Plate Structure for Aircraft Repair Based on Genetic Algorithm

Designing options for aircraft frame plate repair often relies on experience. Development of optimization technique is necessary to obtain optimal design for aircraft frame plate structure. In this paper, a method to optimize the repair parameters using genetic algorithm is proposed for the structural repair of aircraft frame plate. In the design process, the parameters of the reinforced piece are considered, including the type, length, width, thickness, and the layout of the rivets. Compared with the traditional genetic algorithm, the algorithm based on this paper considers the crossover between species and so on, so it can find the optimal solution in a wider design space. The finite element software ABAQUS combined with Python tool is used for parametric modelling and calculation, and the residual stress values of the repaired part is used as the objective function. Finally, a repaired aircraft frame plate structure with best static and dynamic properties is obtained.

A model based material removal simulation for vacuum suction blasting of composites

Automated scarfing of carbon reinforced plastic (CFRP) layers is on its way to support commercial aircraft repair. In the industry, still, the manual scarfing operation is the qualified method. However, automated techniques as milling, laser removal and water jet cutting are in development and showed already good results. Another promising method is vacuum suction blasting (VSB) that was until now in particular used for the roughening of surfaces before adhesive bonding. To find the right adjustment for the parameters many experiments would be necessary accordingly to different CFRP parts with changing layer thicknesses. Simulation is a way to avoid this and to predict the removal result and the settings for the machining parameters. The VSB model uses a pixel method dividing the simulated part surface into smaller volume elements. Experimental data of VSB static blasting spots are the basic for the source matrix. The simulation feeds the matrix with the blasted depth and removal volume for different blasting times. A shifting of columns of the source matrix in the blasting movement direction simulates the movement of the blasting nozzle on the work piece surface. With this, the model can also predict the nozzle feed to remove exactly one complete layer for each scarfing step. In addition, it visualizes the seamless overlapping distance between two blasted tracks. With further adjustments, the model will predict the dynamic removal for varying input parameters such as negative pressure and nozzle distance or blasting agent.

Integrated scheduling method for fleet wave sorties and maintenance of naval distributed platforms

Managing operational command and maintenance support activities for carrier-based aircraft in a multi-platform system is challenging. This research presents an integrated mathematical model for scheduling deployment, sortie, and maintenance of carrier-based aircraft. The model helps decision-makers formulate fleet allocation plans, create sortie flight schedules, and coordinate repairs for future maritime distributed operations. We have introduced a novel bi-level iteration optimization method that improves traditional manual empirical scheduling methods. An advanced version, a two-stage optimization method, can handle a large number of states and solution spaces while ensuring accuracy. Our statistical validation shows that the two-stage optimization method has an insignificant deviation of 1–2% (with an average of −0.91%) from accurate results. Importantly, this method significantly reduces computational time (with an average of 98.25%), which enhances decision-making accuracy and real-time feasibility. Finally, the research discusses a cross-platform linkage mechanism for distributing aircraft repair tasks. This mechanism aims to enhance mission readiness and operational metrics by avoiding backlogs and reducing inefficiencies caused by concentrating maintenance on a single platform. The results of this study provide a foundation for decision-making regarding future naval distributed systems and their operations.

Supplier relationship management and its impacts on purchasing performance in aircraft maintenance, repair, and overhaul in Thailand

Supplier Relationship Management (SRM) has been recognized to play an important role in improving purchasing performance. However, there is no evidence yet to prove this application in the aircraft maintenance, repair, and overhaul (MRO) industry in Thailand. This paper studied SRM which are arm’s-length SRM and cooperative SRM practices, and their impacts on purchasing performance in the aircraft MRO industry of Thailand by using Delphi Technique. Data are collected from in-depth interviews, and by means of a questionnaire. Sample group of this research are 20 specialists who involved with purchasing processes in aircraft MRO. The results show that cooperative SRM improves purchasing performance in all aspects, while arm’s-length SRM only improves purchasing performance in reducing sales price.

ОГЛЯД МЕХАНІЧНИХ ВЛАСТИВОСТЕЙ НАНОКОМПОЗИТІВ НА ПРЕДМЕТ ЇХ ВИКОРИСТАННЯ У ПАРАХ КОВЗАННЯ МЕХАНІЗМІВ АВІАТЕХНІКИ

The object of the review is polymer nanocomposites (PNC), which are used to increase the wear resistance and durability of mechanical contacting surfaces of parts of machines and mechanisms. The goal is to analyze the production and mechanical properties of PNC when they are used in aircraft and helicopter structural units operating in sliding pairs with a large resource. The analysis of existing research and publications on the use of PNC showed that the use of nanocomposites with a plastic base can be recommended for the manufacture of tribological pairs of aircraft parts. It was established that most authors among the considered nanoadditives give preference to nanodiamonds with a concentration in the range of 1...3%, which, in comparison with all other nanomaterials, give a consistently positive result and also have good environmental indicators.It was found that for parts of friction pairs it is possible to provide a friction coefficient of about 0.1 due to the use of composite polymers with ND. The following results were obtained. The performed review will allow to create a regulatory base of nanomaterials, necessary for solving structural and technological solutions in sliding pairs of aviation equipment. According to the analysis of the existing current and actual PNC and their preparation, it was established that a friction coefficient of 0.12 can be ensured for the titanium nanocomposite Ti/ND with a content of 0.35% of ND. It is shown that the galvanic application of nanocoatings on steel with a concentration of nanodiamonds in the solution of 8.0 g/l and a current density of 3.0 A/dm2 can provide the hardness of the composite coating with a maximum value of 5.302 GPa and an average grain size of 4 nm. The scientific novelty of the obtained results is as follows: the production technologies and main mechanical properties of PNC when used in sliding pairs of aircraft parts are analyzed. It was found that the existing publications do not provide enough information about the important parameters of the obtained materials, such as heat resistance, moisture resistance, environmental friendliness, and others. Conclusions. It is recommended to test ND with a concentration in the range of 1...3% on tribological parts of aircraft, as well as in sliding pairs with a long life. However, despite the unique mechanical properties of nanocomposites, the regulatory framework for the design of sliding pairs requires additional research and experiments. The given materials can be useful in carrying out theoretical and experimental studies on extending the resource, operation and repair of aircraft and helicopter parts.

Using the Event Trees in the Automation and Intellectualization of Aircraft Diagnostics and Repair

Using the Event Trees in the Automation and Intellectualization of Aircraft Diagnostics and Repair

Inventory Analysis using Multi-Criteria ABC and ISM Method – A Case Study in Indonesia’s Aviation MRO

Level of inventory plays a crucial role in managing the supply chain in a company, one of which is Aircraft Maintenance, Repair, and Overhaul (MRO) Company. This paper will analyze the material inventory in one of Indonesia’s aircraft MRO companies by categorizing the material and focus on finding the root causes of the high inventory level. ABC Analysis using multiple criteria will be used to categorize the aircraft spare parts inventory. The categories will then be used as the Focus Group Discussion (FGD) topic to gain and determine several root causes of the phenomena. FGD results will then be further analysed using Interpretative Structural Matrix (ISM) to see if there are some interrelationships between root causes. The high inventory level of aircraft spare parts inventory root causes will be specifically determined by analyzing the A category of ABC Classification as this category represents 70% of the inventory. Based on the analysis, it is recommended to solve the root causes extracted from the ISM first to lower the inventory level. This study will be useful for managers to determine the strategy to make the inventory lower impacting on the increase of company’s profit increase.

A Comparative Study between Paper and Paperless Aircraft Maintenance: A Case Study

The rapid growth of airlines over the last period has led to the development of the aviation industry, resulting in increased requirements for ancillary services. Nowadays, the demand for the use of paper-based documents is increasing day by day as airlines encourage passengers to use more ancillary products. One of the most important issues in the aviation industry is flight safety. The procedures and instructions required for all aviation operations are organized in accordance with the regulations and printed on paper in accordance with the demands. For this reason, since it is mandatory to keep all aircraft maintenance, repair, and operation records on printed paper and to keep them for a certain period of time, aircraft fly with almost their entire weight on paper. Considering the global hazards in the world, although the aviation sector is the least environmentally damaging of all transportation sectors, new solutions have been sought to make aviation operations less harmful to the environment, minimize errors and risks, allow for faster communication, and be safer and more sustainable. In order to meet the demands, studies on reducing the use of paper have been brought to the agenda. In this study, after a literature review, real data from a maintenance, repair, and overhaul organization are used to suggest digital conveniences that can save costs, increase productivity, save space, facilitate documentation and information sharing, keep personal information more secure, and help the environment through paperless living.

Visualising dynamics in innovation ecosystems: A new method and demonstration in the commercial aircraft MRO ecosystem

A review and evaluation of 34 visual methods for ecosystem research revealed that there was no method to visually capture the dynamics of innovation ecosystems. To fill this gap, we develop and demonstrate a new visual method, the ecosystem dynamics mapping (EDM) language, for capturing and analysing (i) structural elements, (ii) structural changes and (iii) dynamic forces in evolving innovation ecosystems over time.To develop the EDM language we applied the design science research methodology (DSRM), conducting a demonstration case in the commercial aircraft maintenance, repair and overhaul (MRO) sector. The sector's innovation ecosystem is currently experiencing profound dynamics, with a focus in this paper specifically on dynamics that result from servitizing manufacturers. For the demonstration case, we conducted 18 in-depth semi-structured interviews with 10 decision-makers at a large incumbent service provider, producing a total of 13 ecosystem dynamics maps.This study attempts to make three contributions. First, it identifies, summarises and evaluates the existing ecosystem visualisation methods. Second, we introduce the new EDM language for visualising the dynamics of innovation ecosystems. Third, we present an EDM demonstration case validating its applicability. The EDM language can be used by researchers, practitioners and policy-makers to better understand how innovation ecosystems are changing, thereby supporting strategic decision-making or policy interventions.

The Problem of Production Situations Identifi cation in the Systems of Production Processes Management of an Aircraft Repair Enterprise

This research provides a new approach to solving the problem of identifying emergency situations in the processes of aircraft repair work by forming a metric space of emergency situations and determining the distance between its points. The main stages of repair of Mi-8 helicopters and their modifications at a typical aircraft repair facility are described. The main stages of solving the problem of identifying production situations are determined. Model has been formed to classify the characteristics of production situations that arise during the repair of Mi-8 helicopters. When analyzing the production situation, it is compared with known situations recorded in the database. If its complete coincidence with known situations is found in the metric space of production situations, then the situation is considered known, the decision maker is issued a list of documents. Otherwise, in the metric space of situations, the point closest to the situation that has arisen is determined, and management personnel are given documents. After the end of the production situation, the updated information on the data, documents and recommendations used by the management personnel in the decision-making process is entered by experts into the computer memory, and the situation itself is included in the database used by the management system. A software package has been developed as part of the production process management systems of an aircraft repair company. The efficiency indicators of the implementation of the identification system of complex production situations at the enterprise are determined.

The Influence of Repair Quality on Aircraft Spare Part Demand Variability

Accurate estimation of spare part demand is challenging in the case of intermittent or lumpy demand, characterised by infrequent demand occurrence and variability in demand size. While prior research has considered the effect of exogenous variables on spare part demand, there is a lack of research considering the effects of repair quality and aggregated spare part demand behaviour across fleets of assets under the influence of multiple simultaneously acting drivers of failure. This research provides new insights towards the problem of estimating variable spare part demand through modelling and simulation of the effects of multiple, simultaneously considered spare part demand drivers. In particular, a contribution to the state of the art is introduced by the use of a Branching Poisson Process (BPP) to model repair quality effects for spare part demand generation in conjunction with several demand drivers. The approach is applied in a numerical study which involves component failure characteristics based on real-life data from an aircraft maintenance, repair and overhaul (MRO) provider. It is shown that repair quality improvements drive down the variance in the demand and the total number of failures over time, and outperform the effect of environmental drivers of failure in terms of demand generation.

Opportunities for Civil Aircraft Maintenance, Repair and Overhaul in India

The Indian airline industry is expected to see double digit growth over the next decade as the economy grows between 8-10% GDP, as structural weaknesses are removed, infrastructure strengthened and much needed capital (domestic and foreign) becomes available. It is now perceived that there is already lack of adequate infrastructure for maintenance, repair and overhaul (MRO). Much of the engine, airframe and component MRO are presently being carried out abroad. As of now, there are no major independent MROs that can cater for this large fragmented market. It was felt by the Aeronautical Society of India to set up a Committee to study opportunities for MRO in India. The Committee report [1] details the different types of airframe MRO that are required including aircraft C and higher checks, engines and other equipment. The report encompasses a detailed study of manpower requirements, structure of the MRO organisation, training opportunities apart from providing a basic cost and revenue structure for any MRO. This article provides a brief overview of the report.

Nanocomposites for Aircraft Applications

The steady increase in jet fuel prices in recent years has accelerated the quest for greater economy in airline operations. While improvements in aerodynamic efficiency, engine fuel efficiency, etc., have been sought, lighter and stronger materials for aircraft structural components remain a very important goal. The percentage of advanced composites, utilizing carbon fibers, in modern aircraft has reached 50 percent. The trend now is to use nano reinforcements such as graphene and carbon nanotubes to further reduce the structural weight. Due to the difficulties in fabricating nanocomposites with a high enough volume fraction of nano reinforcement, the nano reinforcements are either added to the polymer matrix or grown on the carbon fibers. The nano reinforcements are multi-functional; thus, in addition to contributing strength, they contribute to other properties such as electrical conductivity which in turn enhances the lightning strike protection, electrostatic discharge, electromagnetic shielding, etc. This paper summarizes these aspects and also describes the applications of nanocomposites in aircraft interiors, brake components, aircraft repair, etc.