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ALERT AGUSTA 21017 Cascina Costa di Samarate (VA) Italy Via GiovanniAgusta, 520 A FINMECCANICA COMPANY Tel.: +390331 229111 - Fax: +390331 229605-222595
TRANSLATION OF BOLLETTINO TECNICO N° 109EP-1 Technical content of this Bollettino Tecnico is E.N.A.C. - R.A.I. approved The E.N.A.C. - R.A.I. states mandatory compliance with inspections, modifications DATE July 21, 1998 or technical directives and related time of compliance by means of relevant Prescrizioni di Aeronavigabilita. REV. B December 19, 2000 this bulletin is: Compliance with MANDATORY MODELS AFFECTED: A109E.
SUBJECT: INSPECTION OF THE TIP CAP OF MAIN ROTOR BLADES P/N 709-0103- 01 (ALL DASH NUMBERS).
REASON: To inspect tip cap of subject blades for presence of debonds and/or cracks.
HELICOPTERS AFFECTED:
All main rotor blades P/N 709-0103-01 up to S/N 1428 included, preceded by code A5 or EM, installed on Agusta A109E helicopters or stocked parts.
NOTE The main rotor blades P/N 709-0103-01 that have replaced the tip cap and have installed the new tip cap P/N 709-0103- 29-109 do not require compliance with this Bollettino. The P/N 709-0103-29- 109 is marked on upperside of tip cap (in the area indicated in Figure 1).
COMPLIANCE:
Within and not later than ten (10) operating hours from the receipt of this Bollettino and subsequently every twenty-five (25) operating hours.
An appropriate entry should be made in the aircraft log book upon accomplishment.
If ownership of aircraft has changed, please, forward to new owner.
ALERT Page 1 016 | E
B.T. 109EP-1.
DESCRIPTION:
Cases of openings on tip cap leading edge of blades P/N 709-0103-01 have occurred, with subsequent increase of helicopter vibratory level. The investigation has evidenced the presence of extense areas of debond of the honeycomb core, causing a "pulsated" effect on tip cap, leading to cracks on leading edge (joint line of shells) of tip cap.
This Bollettino is issued with the purpose of providing an inspection (upper and lower sides) using a hammer for presence of voids:
B • between metal shells and honeycomb core of the tip cap;
• tip cap and blade joint area.
In addition this Bollettino prescribes a liquid penetrant inspection to determine for possible presence of cracks or leading edge (welded joint line of the tip cap shells).
REQUIRED MANPOWER:
One and-a-half (1.5) estimated manpower hours are required for each main rotor blade for compliance with this Bollettino.
WARRANTY: If during the accomplishment of this Bollettino the tip cap is found outside the allowable limits please inform Agusta.
REQUIRED MATERIALS:
The following consumable materials are required to accomplish this Bollettino:
abrasive paper grit N° 320 or more fine solvent (exane, or petroleum ether, or aliphatic naphtha according to TT-N-95 type 2) or solvent 9PR5 available from BRENT International;
B visible dye penetrant P6R available from BRENT International;
nonaqueous wet developer 9D1B spray available from BRENT International;
one or more white light sources able to provide an illuminance of at least 1000 lux on inspection area.
Page 2 of 6
B.T. 109EP-1 Alternative products to the solvents, penetrant and developer specified above are permitted provided that:
they comply to the requirements of AMS2644 (class 2 for the solvent, type 2 and method "c" for the penetrant and form "e" for the developer);
they are listed in the pertinent QPL-AMS-2644-1;
the penetrant and developer are produced by the same company.
SPECIAL TOOLS: N.A.
WEIGHT AND BALANCE CHANGES: N.A.
REFERENCES:
Pertinent Maintenance Manual.
PUBLICATIONS AFFECTED:
Pertinent Maintenance Manual.
COMPLIANCE INSTRUCTIONS:
NOTE The procedure reported below is applicable to each one of the four main rotor blades, if affected by this Bollettino.
1. Using the steel hammer P/N 109-3101-58-1 and in accordance with the pertinent Maintenance Manual, perform a detailed inspection of the blade tip cap (upper and lower sides) for presence of voids:
• between metal shells and honeycomb core (refer to figure 1);
• tip cap to blade bondage area (in this area no debond voids are permitted).
Page 3 of 6 | B
B.T. 109EP-1
CAUTION tapping inspection with the hammer must be carried out by skilled personnel, able to identify defects if present on the bonded components. If skilled personnel is not available please contact Agusta.
Visually inspect the tip cap (upperside and lowerside) for swellings and/or deformations.
Using the visible dye penetrant method, inspect the tip cap leading edge along the welded joint line of the shells for presence of cracks as follows (refer to figure 1):
NOTE 1 The following inspection does not require blade removal from helicopter.
NOTE 2 The following operation must be accomplished at the first application of the liquid penetrant inspection.
3.1. Using abrasive paper grit n° 320 or more fine, remove the paint from area B, on both upper and lower sides, inboard 5 to 10 mm from leading edge and starting at 30 mm from the trailing edge. Mask surrounding painted areas using adhesive tape.
B
3.2. Perform liquid penetrant inspection as follows:
CAUTION Personnel conducting the liquid penetrant inspection must be qualified in accordance with the ASNT practice SNT-TC-1A or other equivalent practice standard. The blade, the penetrant and ambient temperatures shall be between 4 and 45°C.
3.2.1. Thoroughly degrease inspection area using a cloth soaked in solvent (refer to paragraph REQUIRED MATERIALS).
Leave solvent to completely evaporate.
3.2.2. Using adhesive tape mask trailing edge inboard for approximately 30mm to avoid possible penetrant infiltration in the tip cap.
Page 4 of 6
B.T. 109ЕP-1
3.2.3. Apply the penetrant in the inspection area extending approximately 5mm inboard from trailing edge (refer to view A of figure 1), on both upper and lower sides.
Penetrant dwell time shall be 30 to 40 minutes.
3.2.4. Remove excess penetrant with a clear dry cloth followed by a cloth dampened in solvent until the background color has been completely removed.
NOTE Do not directly pour the solvent on the inspection area.
3.2.5. Apply a thin and uniform layer of developer 9D1B, after 10 to 15 minutes illuminate area to 1000 lux and examine it presence of cracks.
3.2.6. Upon completion of inspection, clean affected area with a clean dry cloth followed by a cloth dampened in solvent.
4. The blade that show debonds voids which exceed the prescribed limits of the pertinent Maintenance Manual and/or swellings, deformations and/or cracks, must be removed from service.
In this case, please inform immediately Agusta.
NOTE The inspections required with this Bollettino are not applicable if tip cap replacement with new cap P/N 709- 0103-29-109.
The replacement is carried out by Agusta or authorized Service Station.
5. Return the helicopter in ready to flight condition.
Page 5 of 6 1 B
B.T. 109EP-1
TIP CAP 1P/N 709-0103-29-109
LAP PLATE MARKING
163.0 INSPECTION AREA OI
THE LEADING EDGE
115.0 VIEW A AREA
187.0 HONEY COMB CORE
29.5 B
27.0 221.0
273.0
INSPECTION AREA ON
PAINTED AREA
THE LEADING EDGE
DIMENSIONS IN MILLIMETERS VIEW A ~5 FIGURE 1 Page 6 of 6