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BACK IN
IN THE
THE AIR
AIR FASTER!
FASTER !

INTEGRATED SOLUTIONS FOR RAPID AIRFRAME REPAIRS

AND MANUFACTURING IMPROVEMENTS
101 Convention Center Drive Ste. 700
Las Vegas, NV 89109
Tel: 702 203-1633
Fax: 702 447-7040

COMPANY PHILOSOPHY

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!

TYPICAL EXAMPLE: FUEL LEAK

Currently, a fuel leak typically takes 36 to 72 hours to be

repaired... (sometimes, a lot longer than that)!

AEROWINGs new technologies can

reduce this time to 6 to 12 hours,
with very good reliability

THE FOUR MOST TIME CONSUMING TASKS

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!

SAME METHODS SINCE 1940s

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

NEW TECHNOLOGY - HELIUM LEAK DETECTION: WHY HELIUM?

HELIUM IS A VERY LIGHT INERT GAS

It is the lightest and smallest inert gas molecule.

It easily flows through very small leak paths.
It permits non destructive and dynamic testing.

NEW TECHNOLOGY HELIUM LEAK DETECTION

HELIUM IS SAFE

Helium is non toxic and non reactive.

Helium is non hazardous.
Helium is non flammable, nor explosive.

NEW TECHNOLOGY

AEROWING - Helium Leak Detection 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
Control System, Engine Bleed Air System, etc.)

AIRCRAFT LEAK DETECTION NEEDS

Oxygen lines in cockpit and cabin

Engine fire suppression
Pitot-static circuits

Engine Bleed System

Windshield, windows and doors

Fuel tank pipes, venting systems

Other components : Bladder Cells, Valves, Slides, etc

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.

HELIUM METHOD - FUEL LEAK MAPPING

INSIDE
INSIDE

OUTSIDE

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

HELIUM METHOD - HELIUM PRESSURE

External Leak
Location

FUEL LEAK
=
Location of sealant
deterioration

The application of Helium pressure on the external leak point

will allow the internal leak source detection.

HELIUM METHOD - HELIUM FLOW DETECTION

Rib

INSIDE
(Fuel tank)
Helium Detector
Sniffer

Skin
OUTSIDE
HELIUM

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

HELITEST WING KIT

Listed in T.O. for KC-135 fleet and C-5

depot use (Robins, AFB)

Safety Probe for

use in hazardous
environments
Class 1, Div. 1
(30 foot hose)

Helitest Wing 3.0 Aircraft Helium Leak Detector Kit

HELITEST WING CONCEPT

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

For use in verifying leak repair BEFORE refueling.
*

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

Difficult areas to work inside (and outside) the tank

RAPID DESEALING SYSTEM

Variable Speed Control

Composite Material Blade
Will Not Harm Structure
Will Not Scratch Primer

Standard Shop Air

50 Units in Use
at Tinker AFB
KC-135 PDM

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

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)

Two Configurations Aircraft Repair and Aircraft Manufacturing

RAPID CURING DEVICE

RAPID CURING DEVICE

100
90
80
70

ABSORPTION SPECTRUM OF
PAINT AND SEALANTS

60
50
40
30
20
10
0
2

9 10

9 10

WAVELENGTH (in microns)

100
90
80
70
60

EMISSION SPECTRUM OF THE

THERMOREACTOR 28 Vdc

50
40
30
20
10
0
2

WAVELENGTH (in microns)

RAPID CURING DEVICE

As heat lamp is applied, material forms a skin, trapping

solvents and micro bubbles

1 DANGER:

Infra Red
Signal from
heat lamp

ignition risk
Narrow
Narrow Spectrum
Spectrum of
of Infra
Infra Red
Red

-Warm air
-Electrical
-Electrical infrared
infrared source
source
like
heat
lamp
like heat lamp

Superficial
Superficial drying
drying
Incomplete
Incomplete
polymerization
polymerization

== poor
poor energy
energy transfer
transfer

Trapped
Trapped solvents
solvents
== bubbling
bubbling risk
risk
Poor
Poor absorption
absorption
No surface skin

Infra Red Signal

from
Thermoreactor

Wide
Wide Spectrum
Spectrum Emission
Emission

SEALANT
SEALANT
Complete
Complete safety
safety
Equal
Equal polymerization
polymerization
throughout
throughout the
the
material.
material.

== good
good energy
energy transfer
transfer
Thermoreactor
Thermoreactor
28Vdc
28Vdc

Evaporated
Evaporated solvents
solvents ==
Excellent
Excellent absorption
absorption

no
no micro
micro bubbling
bubbling risk
risk

RAPID CURING DEVICE

Hardness
66 hours
hours

60

72
72 hours
hours standard
standard cure
cure
Reference hardness

55
50

2.75
2.75 hours
hours with
with
Thermoreactor
Thermoreactor

45
40

Tack free time

35
30

30
30 hours
hours standard
standard cure
cure

25
20
15
10
5
0

Time
0

10

20

30

40

50

60

70

80 (hours)

Sealant PR 1422 B2 NA
(fuel leak repair)

With the Thermoreactor 28 Vdc at 122F

Manufacturers suggested temperature

and humidity conditions ( 73.4F 50% )

RAPID CURING DEVICE

Hardness

55 hours
hours

300

170
170 hours
hours standard
standard cure
cure
Reference hardness

250

200

150

100

50

50

100

150

200

Time
(hours)

Polyurethane paint PU66 ( COURTAULDS )

With
With the
the Thermoreactor
Thermoreactor 28
28 Vdc
Vdc at
at 122F
122F

Usual
Usual temperature
temperature and
and hygrometry
hygrometry
conditions
conditions (( 73.4F
73.4F 50%
50% ))

Manufacturing Configuration

Operated by Factory A.C. Electrical

Power

Tank Pressurization System TPS

Easily configured to most aircraft tank systems

TPS: VENT PLUGS

A new generation
of
Vent Plugs
~
No parts removal / Rapid Testing

Patented Process

TPS: CONTROL PANEL

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

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
EUROCOPTER

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
ROYAL AUSTRALIAN AIR FORCE