AviZone

                         Boeing has released a video showing off the weight and strength on this revolutionary breakthrough, and saying it is one of the strongest but lightest materials ever—so light that it can rest on top of a dandelion without destroying it.  Microlattice is a 3D open-cellular polymer structure made up of interconnected hollow tubes, each with a wall 1000 times thinner than a human hair.  Inspired by the structure of bones, the material was originally developed in 2011 by Boeing’s HRL Laboratories. It’s 99.9 per cent hollow and claims to be 100 times lighter than Styrofoam, so could microlattice be the future for aeronautical design? ‘

EUROCOPTER EC135  29/08/2015        FOD.                                                                                                                   Rag ingested into rotor brake and onto both engine intake grills.  Momentary illumination of the rotor brake caution was observed. Brake handle confirmed in the off position. Caution illuminated again approx 5 secs later for approx 2 secs. All other indications normal. Emergency checklist consulted and flight continued to destination with no further cautions. Post flight inspection with engineer revealed evidence of ingestion of a rag past the rotor brake and onto both engine intake grills.         ...

CESSNA 404       CONTINENTAL 520               Scheduled maintenance         24/09/2015                      Smoke from engine on start-up. Caused by a rag which had been inadvertently left inside the engine by a trainee engineer. Appropriate action has been taken. A pilot was asked to conduct a post-maintenance engine run follow rectification of an oil leak. Engine number one was started normally. On start of engine no.2 smoke was noted from the number 1 engine. After a short period of monitoring the pilot elected to shut down both engines and without further delay, exited the aircraft with the Fire Extinguisher and requested assistance. A fire extinguisher was discharged through the louvre at the rear of the upper engine cowling whilst another engineer gained access to the engine via the side access panel. Investigation Findings Once the engine cowling was o...

PIPER PA28   LYCOMING  360 FAMILY            22/08/2015                 Engine failure.            At 2 mins and 15 seconds (2nm north of the airfield and at approx. 1,250 ft) a massive bang was heard coming from the engine, instant power loss and Engine T&P’s went into the red and dropped straight down to no reading. Pilot declared a Mayday emergency (Engine Failure) still on Seething radio frequency (122.60), with the intention of returning to the airfield for an attempted force landing. Seething Air ground radio confirmed that runway 24 could be used and the Fire & Rescue team were on standby at the Alpha hold to follow us down the runway.         At around 1nm to the airfield and attempting to keep high and fast rather than low and slow the aircraft was still at around 800ft so continuous slide slipping and position changes were used, flaps wer...

EUROCOPTER EC135  TURBOMECA, FRANCE         11/09/2015                       Fuel indications inaccurate. Main fuel tanks sensors removed and cleaned before aircraft returned to service.                       Main fuel tank indications began to vary to an uncommon amount over two days. The fuel level would differ between 5-10 kilos depending on the altitude of the aircraft in various phases of flight. By the end of my last shift and arriving back at base the main tank fuel level went from 100kg in the main to 64kg whilst taxiing from the runway to the hangar. Throughout all flights over the 2 days the supply tanks indicated full without any change even when the fuel in the main tank became low. In my experience the supply tanks often drop a few kilos then fill back up to capacity.                  MEL con...

16/08/2015 Climbing out, I was just levelling off and as I reduced power there was a load bang and a rush of air. Checking around I found the rear seat passenger was pointing at the window. It took a moment to realise it was missing. I even stuck my fingers out through the hole but sure enough it was gone. While the loss of the window did not affect the handling of the aircraft there was a risk of personal injury from the shrapnel. One piece flew forward and bounced off the instrument panel. I think it was fortunate the rear seat passenger was sat on the right where she was unharmed. I reduced speed and after confirming there was no affect on the aircraft handling and the passengers were unharmed we continued and made an uneventful landing. The window was the last remaining original piece of Perspex on the 1967 aircraft.

            FAA recommend that owners, operators, and maintenance technicians and inspectors visually inspect and confirm their findings using eddy current on the affected Cessna models utilizing aft fin attachment fitting, part numbers 0431009-1/-2/-3, for cracks and corrosion. This should be done repetitively at  100 hours  intervals following inspection procedures described in the applicable Cessna SID located in the table of SIDs. Note that it may be beneficial for the inspection to be accomplished in conjunction with compliance to AD 80-11-04.          FAA and Textron Aviation (Cessna) have been aware of cracking of the aft fin attachment fitting; and have previously issued a number of airworthiness publications to inform owner, operators, and maintenance technicians and inspectors. Cessna issued Service Bulletins (SE74-10 and SE78-62) in addition to the specific inspections noted in the referenced SID. Additionally,...