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management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements
management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements
Jan 28, 2025
One of the most significant repair costs an aircraft owner encounters is the engine overhaul. Whether dealing with General Aviation (GA) piston aircraft or turbine-powered business jets, the overhaul process can be challenging and expensive. At Boeing, we are committed to supporting our customers by supplying parts for virtually every step of the overhaul process.
Piston and turbine overhauls: A similar approach
1. Disassembly and cleaning
The first step in the overhaul process is disassembly and cleaning. Take special care during this phase to avoid damaging parts that may be reused or repaired. Our portfolio of aerospace-grade cleaning products, including cleaners and degreasers, is designed to facilitate this critical step.
2. Replacement of components
Once the cleaning is complete, parts known to need replacement are removed and scrapped. In GA aircraft, components like pistons and cylinders are often replaced immediately to ensure the engine's longevity until the next overhaul. When replacing cylinder assemblies, our Balance Packs from Continental Aerospace provide a set of balanced pistons, minimizing vibration concerns and enhancing performance.
3. Inspections and testing
For parts that may be reused, dimensional inspections and Non-Destructive Testing (NDT) procedures using inspection chemicals, such as selected products from Magnaflux, are essential to determine their feasibility for reuse. Turbine overhauls follow a similar process, beginning with the removal of life-limited items that are nearing the end of their service life. Components such as stator assemblies and combustion parts undergo thorough inspections and NDT to assess their repairability.
4. Parts availability
Our extensive inventory of GA and turbine engine parts from OEMs like Continental, General Electric, Lycoming, Pratt & Whitney, and Rolls-Royce can be found on our website, ensuring customers receive the correct parts for their needs.
The Importance of fuel systems
Fuel systems are another vital component of the overhaul process. Fuel nozzles must be cleaned and verified for flow and spray pattern, as incorrectly patterned fuel can create hot spots on pistons and significantly degrade engine performance. This includes fuel pumps and other components of the fuel system, with many OEMs offering both new and remanufactured options that meet current specifications, providing customers with choices in terms of price and availability. Explore Boeing's array of fuel system components from various suppliers to find the right fit for your requirements.
Assembly: Precision and care
After inspections are complete and repairs are made, the engine is ready for assembly. This stage can be lengthy and requires meticulous attention to detail, utilizing specialty tools and precise measurements. Assembly fluids, adhesives, greases, and gaskets are crucial in ensuring that every component is correctly positioned. Mechanics must account for every nut, bolt, and tool to prevent Foreign Object Damage (FOD), which can jeopardize hours of hard work.
Once assembled, the engine is prepared for testing. Oils and lubricants, such as AeroShell and Mobil Jet, are applied to ensure smooth operation.
Testing and certification
During testing, the engine's required power is verified and checked for leaks and vibrations. If all parameters meet the necessary standards, the engine is removed from the test cell and sent for preservation before shipping. Documentation, including logbook entries, is completed, and an airworthy certificate is issued. Should any inspection or parameter fail to meet standards during testing, the engine is returned for rework and recycled through testing until all criteria are satisfied.
Essential tools for aviation engine overhaul
For a successful aviation engine overhaul, a variety of specialized tools are essential to ensure precision, safety, and efficiency. We provide and sell tools from notable suppliers such as Barfield, Kell-Strom, and Midwest Aircraft Tooling, recognized for their high-quality tooling solutions tailored for aircraft maintenance. Utilizing the right tools from these reputable suppliers is crucial for achieving optimal engine performance and reliability.
Being able to gain suitable and safe access to work at heights on and around the aircraft is essential. Our line of aerospace ladders and work platforms by Metallic Ladder are ideally suited for this purpose.
Conclusion: Planning for the future
Engine overhaul is essential for aircraft owners, whether for weekend leisure flights or business operations. Understanding the overhaul process and the importance of quality parts can significantly impact the longevity and performance of your aircraft. At Boeing, we are here to support you with the right products and expertise to ensure your engine overhaul is a success.