Appendix 2 Section 7 – Potential Impact on Regulatory Requirements Note: The regulatory requirements identified below, which are inclusive up to Amendment 20 of 14 CFR part 33, are intended as a guide to applicants when determining the applicable regulations to which they must show compliance. Those requirements listed as “Could be affected” highlight the regulations whose compliance findings are typically affected by the component or part that this template is addressing.
This guide is not all-inclusive and the applicant remains responsible for identifying the certification basis of the product on which their PMA part is to be installed.
Applicable 14 CFR Part 33 Regulatory Requirements Comments Subpart A – General
1. 33.4 Instructions for Continued Airworthiness Could be affected
2. 33.5 Instruction manual for installing and operating the engine
3. 33.7 Engine ratings and operating limitations
4. 33.8 Selection of engine power and thrust ratings Subpart B – Design and Construction;
General
5. 33.14 Start-stop cyclic stress (low cycle fatigue)
6. 33.15 Materials
7. 33.17 Fire prevention Could be affected
8. 33.19 Durability Could be affected
9. 33.21 Engine cooling Could be affected
10. 33.23 Engine mounting attachments and structure
11. 33.25 Accessory attachments
12. 33.27 Turbine, compressor, fan, and turbosupercharger rotors
13. 33.28 Electrical and electronic control systems
14. 33.29 Instrumentation connection 121
Appendix 2 Subpart E – Design and Construction;
Turbine Aircraft Engines
15. 33.62 Stress analysis
16. 33.63 Vibration Could be affected
17. 33.65 Surge and stall characteristics Could be affected
18. 33.66 Bleed air systems
19. 33.67 Fuel system
20. 33.68 Induction system icing (Operability aspects)
21. 33.69 Ignition system
22. 33.71 Lubrication system
23. 33.72 Hydraulic actuating system
24. 33.73 Power or thrust response
25. 33.74 Continued rotation
26. 33.75 Safety analysis
27. 33.76 Bird ingestion (Operability aspects of ingestion)
28. 33.77 Foreign object ingestion (Operability aspects of ingestion)
29. 33.78 Rain and hail ingestion
30. 33.79 Fuel burning thrust augmenter Subpart F – Block Tests; Turbine Aircraft Engines
31. 33.83 Vibration test
32. 33.85 Calibration tests
33. 33.87 Endurance test Could be affected Durability
34. 33.88 Engine over temperature test
35. 33.89 Operation test
36. 33.90 Initial maintenance inspection 122
Appendix 2 Subpart F – Block Tests; Turbine Aircraft Engines
37. 33.91 Engine component tests
38. 33.92 Rotor locking tests
39. 33.93 Teardown inspection
40. 33.94 Blade containment and rotor unbalance tests (Weight changes)
41. 33.95 Engine-propeller system tests
42. 33.96 Engine tests in auxiliary power unit (APU) mode
43. 33.97 Thrust reversers
44. 33.99 General conduct of block tests
45. Part 33 - Appendix A – Instructions for Continued Airworthiness Could be affected
46. Part 33 - Appendix B - Certification Standard Atmospheric Concentrations of Rain and Hail 123
Appendix 2 Template #14: VSV Lever Arms Nomenclature for Generic Component Features (all features may not be applicable) 124
Appendix 2 Section 1 – Part Functional capability, i.e., the action(s) that the part is designed to perform in the product Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 1-1 LCF, HCF, tensile capability
• Material mechanical/metallurgical/physical properties
• Dysfunction of actuation system leading to stall, component failure Verify capability 1-2 Galvanic corrosion • Compatibility of lever arm and pin material • Dysfunction of actuation system leading to stall, component failure Verify compatibility in operating environment 1-3 Radial preload • Relative radial position of interface surfaces • Dysfunction of actuation system due to lever arm fatigue or excessive wear Verify dimensional characteristics Section 2 – Part Shape, size, dimensions and other physical measurable parameters, and interconnectivity with an engine integral part/system Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 2-1 Slot • Width
• Thickness
• Corner radii Incorrect fit leading into fretting at vane interface Excessive wear lead into vane actuation failure Fatigue failure
• Dimensional process control and inspection 2-2 Pin • Location relative to slot
• Diameter Incorrect VSV travel leading to stall • Dimensional process control and inspection 2-3 Spherical bearing • Location relative to slot
• Allowable misalignment Incorrect VSV travel leading to stall • Dimensional process control and inspection 2-4 Web geometry • Cross sectional properties Dysfunction of lever arm through tensile, LCF or HCF Interference with case feature leading to limited travel
• Dimensional process control and inspection 125
Appendix 2 Section 3 – Part Materials and Processes – Properties Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 3-1 Chemistry • Major elements - % variation
• Impurities
• Poor mechanical or environmental properties Material selection and process control 3-2 Physical properties • Coefficient of thermal expansion • Excessive stresses
• Interference with surrounding hardware Verify:
• Acceptable stresses
• Lever arm “fit” in hot condition 3-3 Mechanical /metallurgical properties
• Modulus
• Wrought structure
• Hardness/grain size
• Compressive/tensile (UTS, YS)
• LCF, HCF
• Long term metallurgical stability
• Excessive strain-controlled stress
• Undesirable natural frequency
• Low material properties Verify:
• Acceptable stresses
• Adequate material properties
• Operational effects accounted for
• Relevant properties are used 3-4 Environmental resistance
• Corrosion Cracking at pin/arm interface due to galvanic attack Verify acceptable galvanic couples Section 4 – Part Materials and Processes - Processing Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 4-1 Heat treatment • Time @ temperature and ramp rates
• Manufacturing sequence Incorrect morphology leading to low material properties Process control and sequencing 4-2 Shot peen • Intensity
• Coverage Fatigue capability degradation lead to potential lever arm dysfunction Process control 4-3 Material removal
- Non traditional
- Conventional machining Micro cracks or recast:
• Inherent to the process
• Due to abusive machining Fatigue capability degradation, due to:
• Surface finish
• Stress risers
• Chemical attack Cracking initiation from micro-cracks or re-cast • Verify part is tolerant to proposed limits
• Process control 4-4 Non-destructive testing (NDT)
• Acceptance limits
• Sensitivity Cracking from excessive defect size Verify part is tolerant to allowable defects 4-5 Process sequencing including coating Significant process identification and substantiation
• Inspection
• Manufacturing
• Process substantiation Inadequate final part form, or defect “escape”, bushing dysfunction Verify adequate control of processes and parameters 4-6 Pin riveting • Head and hole geometry
• Assembled condition Inadequate assembly lead to wear/fatigue cracking and riveted joint dysfunction Verify adequate control of processes and parameters 126
Appendix 2 Section 5 – Analysis Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 5-1 Operating conditions • Mechanical load and temperature Inadequate part life due to analysis under-predicting part temperature or mechanical stress Perform analysis at relevant operating conditions 5-2 LCF life analysis • Temperature effects
• Mean/alternating stress effects
• Notch effects
• Coating effects
• Mesh size Inadequate part life due to analysis
• Using incorrect properties
• Failing to address the ‘key characteristics’ Use applicable properties Select mesh size to correctly model the geometry 5-3 Variation • Lever arm characteristics Inadequate part life due to variation Verify part is tolerant to variation 5-4 Life calculation • Predicted stress and temperature
• Material properties
• Operating during part life Inadequate part life due to analysis under-predicting Verify correct inputs to lifing process Section 6 – Testing Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 6-1 Durability • Fatigue Component test 127
Appendix 2 Section 7 – Potential Impact on Regulatory Requirements Note: The regulatory requirements identified below, which are inclusive up to Amendment 20 of 14 CFR part 33, are intended as a guide to applicants when determining the applicable regulations to which they must show compliance. Those requirements listed as “Could be affected” highlight the regulations whose compliance findings are typically affected by the component or part that this template is addressing.
This guide is not all-inclusive and the applicant remains responsible for identifying the certification basis of the product on which their PMA part is to be installed.
Applicable 14 CFR Part 33 Regulatory Requirements Comments Subpart A – General
1. 33.4 Instructions for Continued Airworthiness Could be affected
2. 33.5 Instruction manual for installing and operating the engine
3. 33.7 Engine ratings and operating limitations
4. 33.8 Selection of engine power and thrust ratings Subpart B – Design and Construction;
General
5. 33.14 Start-stop cyclic stress (low cycle fatigue)
6. 33.15 Materials Could be affected
7. 33.17 Fire prevention
8. 33.19 Durability Could be affected
9. 33.21 Engine cooling
10. 33.23 Engine mounting attachments and structure
11. 33.25 Accessory attachments
12. 33.27 Turbine, compressor, fan, and turbosupercharger rotors
13. 33.28 Electrical and electronic control systems
14. 33.29 Instrumentation connection 128
Appendix 2 Subpart E – Design and Construction;
Turbine Aircraft Engines
15. 33.62 Stress analysis
16. 33.63 Vibration
17. 33.65 Surge and stall characteristics Could be affected If vane location and angular tolerance is different, compressor stall margin may be affected.
18. 33.66 Bleed air systems
19. 33.67 Fuel system
20. 33.68 Induction system icing (Operability aspects)
21. 33.69 Ignition system
22. 33.71 Lubrication system
23. 33.72 Hydraulic actuating system
24. 33.73 Power or thrust response
25. 33.74 Continued rotation
26. 33.75 Safety analysis
27. 33.76 Bird ingestion (Operability aspects of ingestion)
28. 33.77 Foreign object ingestion (Operability aspects of ingestion)
29. 33.78 Rain and hail ingestion
30. 33.79 Fuel burning thrust augmenter Subpart F – Block Tests; Turbine Aircraft Engines
31. 33.83 Vibration test Could be affected If vane location and angular tolerance is different, blade/vane resonance could be affected.
32. 33.85 Calibration tests
33. 33.87 Endurance test Could be affected Lever arm
34. 33.88 Engine over temperature test 129
Appendix 2 Subpart F – Block Tests; Turbine Aircraft Engines
35. 33.89 Operation test Could be affected
36. 33.90 Initial maintenance inspection
37. 33.91 Engine component tests
38. 33.92 Rotor locking tests
39. 33.93 Teardown inspection Could be affected Visual Inspection
40. 33.94 Blade containment and rotor unbalance tests (Weight changes)
41. 33.95 Engine-propeller system tests
42. 33.96 Engine tests in auxiliary power unit (APU) mode
43. 33.97 Thrust reversers
44. 33.99 General conduct of block tests
45. Part 33 - Appendix A – Instructions for Continued Airworthiness Could be affected
46. Part 33 - Appendix B - Certification Standard Atmospheric Concentrations of Rain and Hail 130
Appendix 2 Template #15: Bushings Ceramic bushing/ Polymeric bushing/ Metallic bushing Nomenclature for Generic Component Features (all features may not be applicable) 131
Appendix 2 Section 1 – Part Functional capability, i.e., the action(s) that the part is designed to perform in the product Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 1-1 Fracture toughness • Material mechanical/metallurgical/physical properties
• Dysfunction of bushing due to cracking from shock load, Verify capability 1-2 Wear characteristics • Wear couple
• Contact area
• Severe wear leading to gas leakage
• Loose fit leading to mating part vibration failure, or rotor and stator contact Verify compatibility in operating environment 1-3 Freedom of rotation • Coefficient of friction
• Hot dimensional fit
• Coefficient of thermal expansion
• Cold fit
• Surface finish
• System seizure-stall, failure of component actuation system
• Increase wear rate due to excessive drag Verify part material and geometry Section 2 – Part Shape, size, dimensions and other physical measurable parameters, and interconnectivity with an engine integral part/system Section/ Number Characteristic Critical to Part Functionality Key Characteristics Part and System Failure Modes Risk Mitigation and Control 2-1 Diameters • OD, ID, Concentricity • Loose fit leading to mating part vibration failure, or rotor and stator contact
• Unacceptable thin bushing due to eccentricity
• Dimensional process control and inspection 2-2 Tolerance • Variance-fluctuations in measurements
• Measurement gauge repeatability and reliability Improper fit leading to premature failure or binding • Dimensional process control and inspection 2-3 Flange • Thickness
• Flatness Interference at assembly preventing freedom of movement • Dimensional process control and inspection 132