-----Original Message-----

From: AOT-Dispatch, Airbus 

Sent: Monday 12 October 2009 10:35

To: AALTUL; 

Subject: A300-600-ATA 55-40- INSPECTION OF RUDDER SIDE SHELLS FOR

POTENTIAL SKIN TO HONEYCOMB DISBOND

FROM : AIRBUS CUSTOMER SERVICES TOULOUSE

TO : ALL A300-600 AIRBUS RESIDENT CUSTOMER SUPPORT MANAGERS

ALL OPERATORS TELEX - ALL OPERATORS TELEX

SUBJECT: A300-600 - ATA 55-40 - INSPECTION OF RUDDER SIDE SHELLS FOR

POTENTIAL SKIN TO HONEYCOMB DISBOND

OUR REF: AOT A300-55A6047 Rev 02 dated 12 OCT 09

OUR PREVIOUS REF: AOT A300-55A6047 Rev 01 dated 08 July 09

AOT A300-55A6047 Rev 00 dated 11 May 09

0. REASON FOR REVISION

This AOT has been revised to:

- Introduce an ultrasonic inspection in the reinforced areas of the

rudders. This ultrasonic inspection replaces the thermography

inspection required by AOT A300-55A6047 Rev.01 and as defined in the

specific Technical Dispositions for reinforced areas location A. The

thermography inspection requirements remain applicable in nonreinforced areas as defined in the specific Technical Disposition

for location D, F, G, H, J, K, L, M and N.

- Introduce minor changes in Technical Disposition

TD/K4/S1/27583/2009, now revised at issue E:

 - References to the specific Technical Dispositions for

location A have been updated

 - References to the specific Technical Dispositions for

the "other areas" at location D, F, G, H, J, K, L, M and

N have been included in appendix A.

 - Titles of Dimensions of inspection drawings have been

revised (page 15).

- Reflect that the ELCh inspection at Trailing Edge area has to be

repeated twice at intervals not exceeding 4500 FC, but no less than

4000 FC since last inspection.
No additional work is required for rudders that have been inspected

through AOT A300-55A6047 Rev.01 dated 08 July 09, except those on which

temporary option II or permanent vacuum loss hole restoration has been

performed according to the specific Technical Dispositions at Location

A: In this case, an additional Ultrasonic inspection within 4500 FC

from restoration date is required.

The revised paragraphs are indicated between **BEG.REV** and

**END.REV**.

1. AIRCRAFT AFFECTED

All A300-600 aircraft equipped with rudders having the Serial Numbers

(SN) listed in Technical Disposition ref. TD/K4/S1/27583/2009 issue E

Table 1, and having a honeycomb core density of 24 kg/m3 (rudders

ticked "x" in column "24kg core").

 Or

All A300-600 aircraft equipped with rudders having the Serial Numbers

(SN) listed in Technical Disposition ref. TD/K4/S1/27583/2009 issue E

Table 1, and having accumulated 13000 FC or more since their first

installation on aircraft at receipt date of this AOT.

Note: Affected rudders listed in Technical Disposition ref.

TD/K4/S1/27583/2009 issue E Table 1, having a honeycomb core density

greater than 24kg/m3 and having accumulated less than 13000 FC at

receipt date of this AOT, are also to be inspected according to the

AOT's instructions. However for these rudders the accomplishment

timescale given in paragraph 4.1.1 has to be considered from the date

when the 13000 FC threshold is reached.

In case a rudder originally fitted on one aircraft (refer to Aircraft

Inspection Report delivery document) has been removed and installed on

another aircraft, it is the responsibility of the operator to apply the

required instructions contained in this AOT to the new aircraft.

If the cross-reference Rudder SN/ Aircraft MSN given in

TD/K4/S1/27583/2009 issue E Table 1 does not reflect the current status

or if the identification plate is missing, contact Airbus.

2. REFERENCED DOCUMENTATION

**BEG.REV**

REF.1: OIT 999.0092/08: ATA55 - Rudder side shell skin disbonding

REF.2: A300-600 SRM 55-41-12 Fig. 1 item 10 & 15

REF.3: Technical Disposition ref. TD/K4/S1/27583/2009 issue E

REF.4. NTM 51-10-26 Part 7 (ELCh inspection)

REF 5: NTM 51-10-28 Part 7 (Vacuum Loss inspection)

REF 6: NTM 55-40-02, Part 10 (Thermography inspection)
REF 7: NTM 51-10-19 Part 5 (Tap test inspection)

REF 8: NTM 51-10-24 Part 4 - NTM Temporary Revision TR 51-006 based on

June 09 revision (Ultrasonic inspection)

**END.REV**

3. REASON

3.1 BACKGROUND

A deformation was visually detected on the rudder side shell of an A319

and an A321 in-service aircraft. Both rudders were sent to Airbus

facilities for further analysis. A review of production records

revealed that the deformations reported on both rudders corresponded to

areas that had been reworked in production.

The conclusion of the investigation is that the disbonding most likely

occurred as a consequence of excessive temperature applied, during a

hot curing rework of the inner skin in production. This rework occurred

outside autoclave.

Such hot curing reworks were also performed on some A300-600 rudders.

Operators were informed thru OIT REF.1 dispatched in November 2008 and

revised in March 2009.

3.2 AIM

For rudders that have been reworked in production with similar hot

curing process, this AOT calls for:

- a one-time Vacuum Loss inspection at rudder shell reinforced areas

- a three(3)-times repetitive Elasticity Laminate Checker (ELCh)

inspection at rudder shell trailing edge area

- a repetitive ELCh inspection in other rudder shell areas; until a

Vacuum Loss inspection is performed (considered as the terminating

action).

4. SHORT TERM ACTION

4.1 PLANNING AND MANPOWER

This AOT is subject to an Airbus Monitored Retrofit Campaign. For

logistic purposes please provide in advance the inspection planning.

Your focal point for the planning and the logistics is:

Wera DIETZ, SEOT2

Customer Services

Phone: +33 (0)5 67 19 14 22
Fax: +33 (0)5 61 93 27 45

Mailto: wera.dietz@airbus.com

4.1.1 ACCOMPLISHMENT TIMESCALE

Accomplishment timescale depends on the locations of the areas to be

inspected, which are fully described in Technical Disposition ref.

TD/K4/S1/27583/2009 issue E.

4.1.1.1 FOR REINFORCED AREAS

The one-time Vacuum Loss inspection described in paragraph 4.2.2.1 must

be performed within 8 months from the receipt date of this AOT.

**BEG.REV**

4.1.1.2 FOR TRAILING EDGE AREA

The ELCh inspection described in paragraph 4.2.2.2 must be performed

within 24 months from the receipt date of this AOT, and repeated twice

at intervals not exceeding 4500 FC but no less than 4000 FC since last

inspection..

Following the third inspection without findings, no further action is

required in the trailing edge area.

**END.REV**

4.1.1.3 FOR OTHER AREAS (LOWER RIB/UPPER EDGE/LEADING EDGE/OTHER

LOCATIONS)

The repetitive ELCh inspection described in paragraph 4.2.2.3.A. must

be performed:

- within 8 months from the receipt date of this AOT

- then, repeated at intervals not exceeding 8 months

- up to accomplishment of the terminating one-time Vacuum Loss

inspection mentioned in paragraph 4.2.2.3.B., that must be

performed within 24 months from the receipt date of this AOT.

Accomplishment of this terminating one-time inspection cancels the

repetitive inspection requirements described in paragraph 4.2.2.3.A.

If the vacuum loss inspection is performed within 8 months from the

receipt date of the AOT, no ELCh inspection is required before or

simultaneously.

4.1.2 MANPOWER

The manpower estimates given below are based on the direct labour to do

the work. These estimates assume that the work will be done by

experienced personnel. They might need to be revised upwards to suit

operators' circumstances.

These estimates do not include the manpower required for repairs in

case of findings.
A) Vacuum Loss inspection:

- Inspection: 1 man-hour per linear meter

- Hole restoration and resin curing time: 12 hours maximum elapsed

time.

B) ELCh inspection:

Note: Refer to Technical Disposition ref. TD/K4/S1/27583/2009 issue E

for identification of inspection area:

- Location B: 4 man-hours

- Location C: 4 man-hours

- Location D: 1 man-hour

- Location E: 0.5 man-hours

- Location F: 3 man-hours.

4.2 DESCRIPTION

4.2.1 JOB PREPARATION AND ACCESS

Refer to Technical Disposition ref. TD/K4/S1/27583/2009 issue E

paragraph "Job preparation".

4.2.2 INSPECTION INSTRUCTIONS

Rudder shells must be inspected only in areas mentioned in Technical

Disposition ref. TD/K4/S1/27583/2009 issue E Table 1.

Example: Rudder SN TS-2074 (end of table 1)

This rudder must be inspected on L/H side shell, at trailing edge

location only as per Technical Disposition location C.

It must be inspected on R/H side shell, at trailing edge location only

as per Technical Disposition location C.

4.2.2.1 FOR REINFORCED AREA

Perform a one-time Vacuum Loss inspection according to Technical

Disposition ref. TD/K4/S1/27583/2009 issue E location A.

Specific inspection instructions are to be requested by mail to:

Jean-Luc BOITEUX, SEES1

Customer Services

Phone: +33 (0)5 61 93 18 69

Fax: +33 (0)5 61 93 36 14

Mailto: jean-luc.j.boiteux@airbus.com

4.2.2.2 FOR TRAILING EDGE AREA

Perform three(3)-times repetitive ELCh inspection according to

Technical Disposition ref. TD/K4/S1/27583/2009 issue E location B, C,

C2, E and P.

4.2.2.3 FOR OTHER AREAS (LOWER RIB/UPPER EDGE/LEADING EDGE/OTHER

LOCATIONS)
A.) Perform a repetitive ELCh inspection according to Technical

Disposition ref. TD/K4/S1/27583/2009 issue E locations D, F, G, H, J,

K, L, M, N.

B.) Perform a one-time Vacuum Loss inspection according to specific

Technical Dispositions. In order to obtain these instructions, please

send a request to:

Jean-Luc BOITEUX, SEES1

Customer Services

Phone: +33 (0)5 61 93 18 69

Fax: +33 (0)5 61 93 36 14

Mailto: jean-luc.j.boiteux@airbus.com

They will be provided in a time-frame compatible with the inspection

planning (refer to paragraph 4.1).

4.2.3 JOB CLOSE UP

Refer to Technical Disposition TD ref. TD/K4/S1/27583/2009 issue E

paragraph "Job close up)".

4.2.4 ACTIONS IN CASE OF FINDINGS

In case of findings, document accurately the relevant inspection report

sheet, and contact Airbus at the following address before next flight

to get further instructions:

SEER1/SEER2/SEER3

Customer Services

Fax: +33 (0)5 61 93 28 73

Mailto:

 region1.StructureRepairSupport@airbus.com

 region2.StructureRepairSupport@airbus.com

 region3.StructureRepairSupport@airbus.com

Or for AOG request

AIRTAC (Airbus Technical AOG Center)

Customer Services

Phone: +33 (0)5 61 93 34 00

Fax: +33 (0)5 61 93 35 00

Mailto: airtac@airbus.com

4.2.5 REPORTING

If there are no findings, report to Airbus within 10 days from the

inspection date of each affected rudder, at the following address:

Jean-Luc BOITEUX, SEES1

Customer Services

Phone: +33 (0)5 61 93 18 69
Fax: +33 (0)5 61 93 36 14

Mailto: jean-luc.j.boiteux@airbus.com

**BEG.REV**

4.2.6 MATERIAL, TOOLING

Adjustable access platform or Cherry Picker

- Inspection equipment for ELCh as per REF.4

- Inspection equipment for Vacuum Loss inspection as per REF. 5

- Inspection equipment for Thermography as per REF. 6

- Inspection equipment for Tap test as per REF. 7

- Inspection equipment for Ultrasonic inspection as per REF. 8

**END.REV**

Note 1: In order for Airbus to provide adequate support to all affected

operators, it is recommended to place a Purchase Order for ELCh tool

two weeks ahead of the first scheduled inspection.

Note 2: A CD-Rom including ELCh familiarization has been shipped to all

affected operators via Airbus Field Service stations.

**BEG.REV**

Note 3: Instructions for restoration of Vacuum Loss inspection holes

are detailed in the specific Technical Dispositions, and can be

performed in 2 steps:

- Temporary restoration (option I): Hole closing with selfadhesive patches, valid for 4500 FC. Correct cover application

has to be ensured by frequent detailed visual inspections at

intervals not exceeding 4 months/500 FH (whichever occurs first),

until permanent restoration is performed, or

- Temporary restoration (option II): Hole filling with resin.

Local ultrasonic inspection in reinforced areas and local

thermography inspection in other areas must be performed before

resin injection. Final restoration has to be performed not later

than 4500 FC.

- Permanent restoration: Hole filling with resin and restoration

of surface protection. Local ultrasonic inspection in reinforced

areas and local thermography inspection in other areas must be

performed before resin injection.

**END.REV**

Note 4: For thermography inspection, as a limited number of equipment

is available for loan from Airbus, necessary Infrared camera could also

be purchased at the following address:

FLIR SYSTEMS

Internet address: <http://www.flir.com/>
5. AOT APPROVAL

The technical content of this AOT has been approved under the authority

of EASA Design Organization Approval number EASA 21J.031.

It is anticipated that this AOT will be rendered mandatory.

6. REPORTING/ACKNOWLEDGMENT

Operators are requested to acknowledge receipt of this AOT within 48

hours after receipt to:

R. LASCOURS, SEE

E-mail: richard.lascours@airbus.com

Fax number +33/(0) 5.61.93.32.73

This acknowledgement can be made through the Airbus RCSM when

available.

Best regards,

E. VAN AELST

VICE PRESIDENT A300/A310/A300-600 PROGRAMME

CUSTOMER SERVICES DIRECTORATE

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